Expandable tubular

ABSTRACT

An expandable tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent application for PCT patent application serial number PCT/US2004/026345, attorney docket number 25791.301.02, filed on Aug. 13, 2004, which claimed the benefit of the filing dates of: 1) U.S. provisional patent application Ser. No. 60/585,370, attorney docket number 25791.299, filed on Jul. 2, 2004, and 2) U.S. provisional patent application Ser. No. 60/495,056, attorney docket number 25791.301, filed on Aug. 14, 2003, the disclosures of which are incorporated herein by reference.

The present application is also a continuation in part of the following: 1) U.S. utility patent application Ser. No. 10/528,498, attorney docket no. 25791.118.08, filed on Mar. 18, 2005, which was the National Stage patent application for PCT patent application serial number pct/us03/25667, attorney docket no. 25791.118.02, filed on Aug. 13, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/412,653, attorney docket no. 25791.118, filed Sep. 20, 2002; 2) U.S. utility patent application Ser. No. 10/528,499, attorney docket no. 25791.121.05, filed on Mar. 18, 2005, which was the National Stage patent application for PCT patent application serial number PCT/US2003/25676, attorney docket no. 25791.121.02, filed on Aug. 18, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/412,544, attorney docket no. 25791.121, filed Sep. 20, 2002; and 3) U.S. utility patent application Ser. No. 10/528,222, attorney docket no. 25791.129.03, filed on Aug. 18, 2005, which was the National Stage patent application for PCT patent application serial number PCT/US2003/025716, attorney docket no. 25791.129.02, filed on Aug. 18, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/412,371, attorney docket no. 25791.129, the disclosures of which are incorporated herein by reference.

The present application is also a continuation-in-part of U.S. utility patent application Ser. No. 10/528,223, attorney docket number 25791.127.03, filed on Mar. 18, 2005, which is a National Stage patent application of PCT patent application serial number PCT/2003/025707, attorney docket number 25791.127.02, filed on Aug. 18, 2003, which claimed the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/412,196, attorney docket no 25791.127, filed on Sep. 20, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/525,402, attorney docket number 25791.120.05, filed on Feb. 23, 2005, which is a National Stage patent application of PCT patent application serial number PCT/US2003/025676, attorney docket number 25791.120.02, filed on Aug. 18, 2003, which claimed the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/405,394, attorney docket no 25791.120, filed on Aug. 23, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/525,332, attorney docket number 25791.119.03, filed on Jul. 5, 2005, which is a National Stage patent application of PCT patent application serial number PCT/US2003/025677, attorney docket number 25791.119.02, filed on Aug. 18, 2003, which claimed the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/405,610 attorney docket no 25791.119, filed on Aug. 23, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/522,039, attorney docket number 25791.106.05, filed on Jan. 19, 2005, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/511,410, attorney docket number 25791.101.05, filed on Oct. 14, 2004 which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/372,632, attorney docket number 25791.101, filed on Apr. 15, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/510,966, attorney docket number 25791.93.05, filed on Oct. 12, 2004, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/372,048, attorney docket number 25791.93, filed on Apr. 12, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/500,745, attorney docket number 25791.92.05, filed on Jul. 6, 2004, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 10/500,745, attorney docket number 25791.92, filed on Dec. 10, 2002, the disclosures of which are incorporated herein by reference.

This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent spplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no. 25791.36.03, which claims priority from provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02, which claims priority from provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, attorney docket no. 25791.38.07, which claims priority from provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application Ser. No. 60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no. 25791.45.07, which claims priority from provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/, filed on Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priority from provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, attorney docket no. 25791.47.03, which claims priority from provisional patent application Ser. No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no. 25791.48.06, which claims priority from provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13, 2003, attorney docket no. 25791.51.06, which claims priority from provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patent application Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, attorney docket no. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No. 09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. 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No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on Sep. 19, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/326,886, attorney docket no. 25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25, 2001, attorney docket no. 25791.62, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent application Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney docket no. 25791.63, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney docket no. 25791.64, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed on Sep. 25, 2001, attorney docket no. 25791.65, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser. No. 09/962,468, filed on Sep. 25, 2001, attorney docket no. 25791.66, which is a divisional of U.S. patent application Ser. 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BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of forming a tubular liner within a preexisting structure is provided that includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.

According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.

According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.

According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.

According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.

According to another aspect of the present invention, an expandable tubular member is provided, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.

According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member is provided that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.

According to another aspect of the present invention, a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member is provided that includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.

According to another aspect of the present invention, a method of manufacturing a tubular member is provided that includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.

According to another aspect of the present invention, an apparatus is provided that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.

According to another aspect of the present invention, an expandable tubular member is provided, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.

According to another aspect of the present invention, a method of determining the expandability of a selected tubular member is provided that includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.

According to another aspect of the present invention, a method of radially expanding and plastically deforming tubular members is provided that includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.

According to another aspect of the present invention, a radially expandable tubular member apparatus is provided that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.

According to another aspect of the present invention, a radially expandable tubular member apparatus is provided that includes: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.

According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.

According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.

According to another aspect of the present invention, an expandable tubular assembly is provided that includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.

According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes: providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21.

According to another aspect of the present invention, an expandable tubular member is provided, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36.

According to another aspect of the present invention, a method of selecting tubular members for radial expansion and plastic deformation is provided that includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.

According to another aspect of the present invention, a method of selecting tubular members for radial expansion and plastic deformation is provided that includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.

According to another aspect of the present invention, an expandable tubular member is provided that includes a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.

According to another aspect of the present invention, a method of manufacturing an expandable tubular member has been provided that includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.

According to another aspect of the present invention, a method for manufacturing an expandable tubular member has been provided that includes providing a material, heat treating the material, quenching the material, and cold working the material, whereby upon cold working, the yield strength of the material is increased.

According to another aspect of the present invention, a method for expanding an expandable tubular member has been provided that includes providing a tubular member, lubricating the tubular member, and expanding the tubular member.

According to another aspect of the present invention, a method for formability evaluation has been provided that includes providing a tubular member, measuring a plurality of stress and strain property parameters for the tubular member, measuring a Charpy V-notch impact value parameter for the tubular member, measuring a stress rupture parameter for the tubular member, measuring a strain hardening exponent parameter for the tubular member, measuring a plastic strain ratio parameter for the tubular member, comparing the parameters measured for first tubular member to a plurality of parameters measured for a second tubular member, and selecting the first or second tubular member to manufacture an expandable tubular member.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength in the range of 60 ksi to 120 ksi, a yield strength in the range of 40 ksi to 100 ksi, a yield strength to tensile strength ratio in the range of 50% to 85%, a minimum elongation of 35%, a minimum width reduction of 40%, a minimum thickness reduction of 30%, and a minimum anisotropy of 1.5.

According to another aspect of the present invention, a method for transforming the yield strength of an expandable tubular member has been provided that includes providing a manufactured tubular member, cold rolling the tubular member, inter-critical annealing the tubular member, expanding the tubular member, and heating the tubular member.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength in the range of 80 ksi to 100 ksi, a yield strength in the range of 60 ksi to 90 ksi, a maximum yield strength to tensile strength ratio of 85%, a minimum elongation of 22%, a minimum width reduction of 30%, a minimum thickness reduction of 35%, and a minimum anisotropy of 0.8.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength in the range of 60 ksi to 120 ksi, a yield strength in the range of 40 ksi to 100 ksi, a yield strength to tensile strength ratio in the range of 50% to 85%, a minimum elongation of 35%, a minimum width reduction of 40%, a minimum thickness reduction of 30%, and a minimum anisotropy of 1.5.

According to another aspect of the present invention, a method for transforming the yield strength of an expandable tubular member has been provided that includes providing a manufactured tubular member, inter-critical annealing the tubular member, expanding the tubular member, and heating the tubular member.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 76 ksi, a tensile strength of approximately 82 ksi, and an elongation of approximately 32%.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a surface, a self lubricating hard coating on the surface, and a self lubricating soft coating on the surface.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength in the range of 40 ksi to 80 ksi, a maximum yield strength to tensile strength ratio of 0.5, a minimum elongation of 30%, a minimum width reduction of 45%, a minimum wall thickness reduction of 30%, and a minimum anisotropy of 1.5.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a friction coefficient of 0.02, whereby the member may be expanded by a force below 100000 lbs.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a lubricant resulting in a friction coefficient of 0.125, a wall thickness of approximately 0.305 inches, and an expansion force of approximately 146000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 25 and a collapse strength of approximately 2400 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a lubricant resulting in a friction coefficient of 0.0.075, a wall thickness of approximately 0.350 inches, and an expansion force of approximately 143000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 22 and a collapse strength of approximately 3250 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.450 inches, and an expansion force of approximately 150000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 17 and a collapse strength of approximately 5800 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.5 inches, and an expansion force of approximately 126000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 15 and a collapse strength of approximately 5350 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.5 inches, and an expansion force of approximately 127000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 15 and a collapse strength of approximately 8400 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a composition, by weight percentage, of 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a composition, by weight percentage, of 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a composition, by weight percentage, of 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.3% Si, 0.16% Cu, 0.05% Ni, 0.05% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a composition, by weight percentage, of 0.03% C, 1.48% Mn, 0.014% P, 0.002% S, 0.16% Si, 0.02% Cu, 0.01% Ni, 0.02% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 16% expansion, approximately a 21% change in yield strength, approximately a 24% change in yield ratio, approximately a 18% change in elongation percentage, approximately a 8% change in width reduction percentage, approximately a 15% change in wall thickness reduction percentage, and approximately a 4% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 15.6% expansion, approximately a 70% change in yield strength, approximately a 25% change in yield ratio, approximately a 67% change in elongation percentage, approximately a 28% change in width reduction percentage, approximately a 7% change in wall thickness reduction percentage, and approximately a 75% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 5% change in yield strength, approximately a 11% change in yield ratio, approximately a 20% change in elongation percentage, approximately a 43% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 52% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 10% change in yield strength, approximately a 3% change in yield ratio, approximately a 30% change in elongation percentage, approximately a 13% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 17% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 46% change in yield strength, approximately a 20% change in yield ratio, approximately a 91% change in elongation percentage, approximately a 15% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 18% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 16% expansion, approximately a 38% change in yield strength, approximately a 20% change in yield ratio, approximately a 11% change in elongation percentage, approximately a 9% change in width reduction percentage, approximately a 4% change in wall thickness reduction percentage, and approximately a 4% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 31% change in yield strength, approximately a 14% change in yield ratio, approximately a 48% change in elongation percentage, approximately a 13% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 12% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 38% change in yield strength, approximately a 21% change in yield ratio, approximately a 55% change in elongation percentage, approximately a 16% change in width reduction percentage, approximately a 9% change in wall thickness reduction percentage, and approximately a 13% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 16% expansion, approximately a 33% change in yield strength, approximately a 26% change in yield ratio, approximately a 30% change in elongation percentage, approximately a 15% change in width reduction percentage, approximately a 9% change in wall thickness reduction percentage, and approximately a 10% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, after a 24% expansion, approximately a 41% change in yield strength, approximately a 27% change in yield ratio, approximately a 40% change in elongation percentage, approximately a 21% change in width reduction percentage, approximately a 16% change in wall thickness reduction percentage, and approximately a 5% change in anisotropy.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 80 ksi after 16% expansion, and a tensile strength of approximately 82 ksi after 24% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 82 ksi after 16% expansion, and a tensile strength of approximately 88 ksi after 24% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 80 ksi before expansion, a tensile strength of approximately 90 ksi after 16% expansion, and a tensile strength of approximately 92 ksi after 24% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 115 ksi before expansion, a tensile strength of approximately 120 ksi after 15.2% expansion; and a tensile strength of approximately 121 ksi after 25.2% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 100 ksi before expansion, and a tensile strength of approximately 126 ksi after 31.3% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a tensile strength of approximately 114 ksi before expansion, and a tensile strength of approximately 140 ksi after 15.6% expansion.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in water at approximately 775° C., a tensile strength of 94 ksi and a yield strength of 56 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in water at approximately 790° C., a tensile strength of 94 ksi and a yield strength of 59 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in water at approximately 735° C., a tensile strength of 94 ksi and a yield strength of 59 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in oil at approximately 775° C., a tensile strength of 84 ksi and a yield strength of 49 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in oil at approximately 820° C., a tensile strength of 82 ksi and a yield strength of 61 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, upon quenching in oil at approximately 750° C., a tensile strength of 109 ksi and a yield strength of 58 ksi.

According to another aspect of the present invention, an expandable tubular member has been provided that includes, by weight percentage, 0.1% C, 1.5% Mn, and 0.3% Si.

According to another aspect of the present invention, an expandable tubular member has been provided that includes martensite in the range of 15% to 30%.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.86, a longitudinal elongation of approximately 14.8%, a width reduction of approximately 38%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.87.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 81 ksi, a yield strength to tensile strength ratio of approximately 0.83, a longitudinal elongation of approximately 14.9%, a width reduction of approximately 38%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.83.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 79 ksi, a yield strength to tensile strength ratio of approximately 0.82, a longitudinal elongation of approximately 15.9%, a width reduction of approximately 44%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 1.03.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.83, a longitudinal elongation of approximately 15.3%, a width reduction of approximately 40%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.92.

According to another aspect of the present invention, an expandable tubular member has been provided that includes an elongation of approximately 21%, a width reduction of approximately 35%, a wall thickness reduction of approximately 38%, and an anisotropy of approximately 0.89.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 77 ksi, a yield strength to tensile strength ratio of approximately 0.82, a longitudinal elongation of approximately 16%, a width reduction of approximately 32%, a wall thickness reduction of approximately 45%, and an anisotropy of approximately 0.65.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 78 ksi, a yield strength to tensile strength ratio of approximately 0.8, a longitudinal elongation of approximately 16%, a width reduction of approximately 31%, a wall thickness reduction of approximately 45%, and an anisotropy of approximately 0.63.

According to another aspect of the present invention, an expandable tubular member has been provided that, upon quenching and tempering, includes a yield strength of approximately 84 ksi, a yield strength to tensile strength ratio of approximately 0.84, a longitudinal elongation of approximately 20.5%, a width reduction of approximately 40%, a wall thickness reduction of approximately 42%, and an anisotropy of approximately 0.94.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.72, an elongation of approximately 35%, a width reduction of approximately 35%, a wall thickness reduction of approximately 33%, and an anisotropy of approximately 0.92.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 90 ksi, a yield strength to tensile strength ratio of approximately 0.88, an elongation of approximately 25%, a width reduction of approximately 22%, a wall thickness reduction of approximately 20%, and an anisotropy of approximately 1.1.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 88 ksi, a yield strength to tensile strength ratio of approximately 0.87, an elongation of approximately 16%, a width reduction of approximately 24%, a wall thickness reduction of approximately 30%, and an anisotropy of approximately 0.76.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 48 ksi, a yield strength to tensile strength ratio of approximately 0.73, an elongation of approximately 38%, a width reduction of approximately 43%, a wall thickness reduction of approximately 49%, and an anisotropy of approximately 0.83.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 46 ksi, a yield strength to tensile strength ratio of approximately 0.69, an elongation of approximately 40%, a width reduction of approximately 50%, a wall thickness reduction of approximately 53%, and an anisotropy of approximately 0.93.

According to another aspect of the present invention, an expandable tubular member has been provided that includes a yield strength of approximately 53 ksi, a yield strength to tensile strength ratio of approximately 0.85, an elongation of approximately 49%, a width reduction of approximately 49%, a wall thickness reduction of approximately 46%, and an anisotropy of approximately 1.1.

According to another aspect of the present invention, an expandable tubular member has been provided that, upon quenching and tempering, includes, after a flare expansion of 42%, an absorbed energy in the longitudinal direction of 125, an absorbed energy in the transverse direction of 59, and an absorbed energy in the weld of 176.

According to another aspect of the present invention, an expandable tubular member has been provided that, upon quenching and tempering, includes, after a flare expansion of 52%, an absorbed energy in the longitudinal direction of 145, an absorbed energy in the transverse direction of 59, and an absorbed energy in the weld of 174.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.

FIG. 2 is a fragmentary cross sectional view of the expandable tubular member of FIG. 1 after positioning an expansion device within the expandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the expandable tubular member of FIG. 2 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the expandable tubular member of FIG. 3 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.

FIG. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 1-4.

FIG. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 1-4.

FIG. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.

FIG. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.

FIG. 9 is a fragmentary cross sectional view of the expandable tubular member of FIG. 8 after positioning an expansion device within the expandable tubular member.

FIG. 10 is a fragmentary cross sectional view of the expandable tubular member of FIG. 9 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.

FIG. 11 is a fragmentary cross sectional view of the expandable tubular member of FIG. 10 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.

FIG. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 8-11.

FIG. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 8-11.

FIG. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.

FIG. 15 is a fragmentary cross sectional view of the expandable tubular member of FIG. 14 after positioning an expansion device within the expandable tubular member.

FIG. 16 is a fragmentary cross sectional view of the expandable tubular member of FIG. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.

FIG. 17 is a fragmentary cross sectional view of the expandable tubular member of FIG. 16 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.

FIG. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.

FIG. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of FIG. 18.

FIG. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.

FIG. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.

FIG. 22 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, an embodiment of a tubular sleeve supported by the end portion of the first tubular member, and a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member and engaged by a flange of the sleeve. The sleeve includes the flange at one end for increasing axial compression loading.

FIG. 23 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes flanges at opposite ends for increasing axial tension loading.

FIG. 24 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes flanges at opposite ends for increasing axial compression/tension loading.

FIG. 25 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes flanges at opposite ends having sacrificial material thereon.

FIG. 26 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a thin walled cylinder of sacrificial material.

FIG. 27 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a variable thickness along the length thereof.

FIG. 28 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a member coiled onto grooves formed in the sleeve for varying the sleeve thickness.

FIG. 29 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.

FIGS. 30 a-30 c are fragmentary cross-sectional illustrations of exemplary embodiments of expandable connections.

FIG. 31 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.

FIGS. 32 a and 32 b are fragmentary cross-sectional illustrations of the formation of an exemplary embodiment of an expandable connection.

FIG. 33 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.

FIGS. 34 a, 34 b and 34 c are fragmentary cross-sectional illustrations of an exemplary embodiment of an expandable connection.

FIG. 35 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.

FIG. 35 b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of FIG. 35 a.

FIG. 36 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.

FIG. 36 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.

FIG. 36 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.

FIG. 37 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.

FIG. 37 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.

FIG. 37 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.

FIG. 38 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.

FIG. 38 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.

FIG. 38 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.

FIG. 39 is an illustration of an exemplary embodiment of a method for manufacturing an expandable tubular member.

FIG. 40 is an illustration of an exemplary embodiment of a method for expanding an expandable tubular member.

FIG. 41 is an illustration of an exemplary embodiment of a method for formability evaluation.

FIG. 42 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 43 is an illustration of an exemplary embodiment of a method for transforming the yield strength of an expandable tubular member.

FIG. 44 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 45 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 46 is an illustration of an exemplary embodiment of a method for manufacturing an expandable tubular member.

FIG. 47 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 48 is an illustration of an exemplary embodiment of a lubricated expandable tubular member.

FIG. 49 is an illustration of an exemplary embodiment of the force needed to expand a plurality of lubricated tubular members.

FIG. 50 a is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 50 b is an illustration of the stress strain properties of a plurality of expandable tubular members.

FIG. 51 is an illustration of an exemplary embodiment of the force needed to expand a plurality of tubular members including different lubricants.

FIG. 52 is an illustration of an exemplary embodiment of the collapse strength of a plurality of tubular members including different lubricants.

FIG. 53 is an illustration of an exemplary embodiment of a plurality of expandable tubular members of different compositions.

FIG. 54 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 16% expansion.

FIG. 55 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 15.6% expansion.

FIG. 56 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 24% expansion.

FIG. 57 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 16% and 24% expansion.

FIG. 58 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 16% expansion.

FIG. 59 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 24% expansion.

FIG. 60 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 16% and 24% expansion.

FIG. 61 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 16% expansion.

FIG. 62 is an illustration of an exemplary experimental embodiment of the tensile characteristics of an expandable tubular member before and after 24% expansion.

FIG. 63 is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion, after 16% expansion, and after 24% expansion.

FIG. 64 is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion, after 16% expansion, and after 24% expansion.

FIG. 65 is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion, after 16% expansion, and after 24% expansion.

FIG. 66 is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion, after 15.2% expansion, and after 25.2% expansion.

FIG. 67 is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion and after 31.3% expansion.

FIG. 68 a is an illustration of an exemplary experimental embodiment of the stress/strain curve for an expandable tubular member before expansion and after 15.6% expansion.

FIG. 68 b is an illustration of the properties of an expandable tubular member.

FIG. 69 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in water at approximately 775° C.

FIG. 70 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in water at approximately 790° C.

FIG. 71 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in water at approximately 735° C.

FIG. 72 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in oil at approximately 775° C.

FIG. 73 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in oil at approximately 820° C.

FIG. 74 is an illustration of an exemplary experimental embodiment of the tensile and yield strength of a tubular member before and after quenching in oil at approximately 750° C.

FIG. 75 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 76 is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 77 a is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 77 b is an illustration of an exemplary embodiment of the stress-strain curve for an expandable tubular member.

FIG. 78 a is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 78 b is an illustration of an exemplary embodiment of the stress-strain curve for an expandable tubular member.

FIG. 79 a is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 79 b is an illustration of an exemplary embodiment of the stress-strain curve for an expandable tubular member.

FIG. 80 a is an illustration of an exemplary embodiment of the properties of an expandable tubular member.

FIG. 80 b is an illustration of an exemplary embodiment of the stress-strain curve for an expandable tubular member.

FIG. 81 is an illustration of an exemplary embodiment of the properties for a plurality of expandable tubular members.

FIG. 82 is an illustration of an exemplary embodiment of the properties for a plurality of quenched and tempered expandable tubular members.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIG. 1, an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14. In several exemplary embodiments, the ends of the first and second expandable tubular members, 12 and 14, are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, the first expandable tubular member 12 has a plastic yield point YP₁, and the second expandable tubular member 14 has a plastic yield point YP₂. In an exemplary embodiment, the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18.

As illustrated in FIG. 2, an expansion device 20 may then be positioned within the second expandable tubular member 14. In several exemplary embodiments, the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16.

As illustrated in FIG. 3, the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 14 to form a bell-shaped section.

As illustrated in FIG. 4, the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12.

In an exemplary embodiment, at least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14, are radially expanded into intimate contact with the interior surface of the preexisting structure 16.

In an exemplary embodiment, as illustrated in FIG. 5, the plastic yield point YP₁ is greater than the plastic yield point YP₂. In this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12.

In an exemplary embodiment, as illustrated in FIG. 6, the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radial expansion and plastic deformation, and a ductility D_(AE) and a yield strength YS_(AE) after radial expansion and plastic deformation. In an exemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater than YS_(PE). In this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process. Furthermore, in this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YS_(AE) is greater than YS_(PE), the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.

In an exemplary embodiment, as illustrated in FIG. 7, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 10 described above with reference to FIGS. 1-4, at least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12. In this manner a bell-shaped section is formed using at least a portion of the second expandable tubular member 14. Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to FIGS. 1-4. Furthermore, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 20, in an exemplary embodiment, at least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24. In this manner a bell-shaped section is formed using at least a portion of the second expandable tubular member 26. Furthermore, in this manner, a mono-diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter.

Referring to FIG. 8, an exemplary embodiment of an expandable tubular assembly 100 includes a first expandable tubular member 102 coupled to a tubular coupling 104. The tubular coupling 104 is coupled to a tubular coupling 106. The tubular coupling 106 is coupled to a second expandable tubular member 108. In several exemplary embodiments, the tubular couplings, 104 and 106, provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108, together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, the first and second expandable tubular members 12 have a plastic yield point YP₁, and the tubular couplings, 104 and 106, have a plastic yield point YP₂. In an exemplary embodiment, the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112.

As illustrated in FIG. 9, an expansion device 114 may then be positioned within the second expandable tubular member 108. In several exemplary embodiments, the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110.

As illustrated in FIG. 10, the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.

As illustrated in FIG. 11, the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108, the tubular couplings, 104 and 106, and at least a portion of the first expandable tubular member 102.

In an exemplary embodiment, at least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108, are radially expanded into intimate contact with the interior surface of the preexisting structure 110.

In an exemplary embodiment, as illustrated in FIG. 12, the plastic yield point YP₁ is less than the plastic yield point YP₂. In this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108, is less than the amount of power and/or energy required to radially expand each unit length of the tubular couplings, 104 and 106.

In an exemplary embodiment, as illustrated in FIG. 13, the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radial expansion and plastic deformation, and a ductility D_(AE) and a yield strength YS_(AE) after radial expansion and plastic deformation. In an exemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater than YS_(PE). In this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process. Furthermore, in this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YS_(AE) is greater than YS_(PE), the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.

Referring to FIG. 14, an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204 a, 204 b, 204 c, and 204 d. In several exemplary embodiments, the ends of the first and second expandable tubular members, 202 and 204, are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, one or more of the radial openings, 204 a, 204 b, 204 c, and 204 d, have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204. In an exemplary embodiment, the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore 206 that traverses a subterranean formation 208.

As illustrated in FIG. 15, an expansion device 210 may then be positioned within the second expandable tubular member 204. In several exemplary embodiments, the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206.

As illustrated in FIG. 16, the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.

As illustrated in FIG. 16, the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202.

In an exemplary embodiment, the anisotropy ratio AR for the first and second expandable tubular members is defined by the following equation: AR=In (WT _(f) /WT _(o))/In (D _(f) /D _(o));

where AR=anisotropy ratio;

where WT_(f)=final wall thickness of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member;

where WT_(i)=initial wall thickness of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member;

where D_(f)=final inside diameter of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member; and

where D_(i)=initial inside diameter of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member.

In an exemplary embodiment, the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204, is greater than 1.

In an exemplary experimental embodiment, the second expandable tubular member 204 had an anisotropy ratio AR greater than 1, and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204 a, 204 b, 204 c, and 204 d, splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result.

Referring to FIG. 18, in an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 are processed using a method 300 in which a tubular member in an initial state is thermo-mechanically processed in step 302. In an exemplary embodiment, the thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo-mechanical processing 302, the tubular member is transformed to an intermediate state. The tubular member is then further thermo-mechanically processed in step 304. In an exemplary embodiment, the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo-mechanical processing 304, the tubular member is transformed to a final state.

In an exemplary embodiment, as illustrated in FIG. 19, during the operation of the method 300, the tubular member has a ductility D_(PE) and a yield strength YS_(PE) prior to the final thermo-mechanical processing in step 304, and a ductility D_(AE) and a yield strength YS_(AE) after final thermo-mechanical processing. In an exemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater than YS_(PE). In this manner, the amount of energy and/or power required to transform the tubular member, using mechanical forming processes, during the final thermo-mechanical processing in step 304 is reduced. Furthermore, in this manner, because the YS_(AE) is greater than YS_(PE), the collapse strength of the tubular member is increased after the final thermo-mechanical processing in step 304.

In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have the following characteristics: Characteristic Value Tensile Strength 60 to 120 ksi Yield Strength 50 to 100 ksi Y/T Ratio Maximum of 50/85% Elongation During Radial Expansion and Minimum of 35% Plastic Deformation Width Reduction During Radial Expansion Minimum of 40% and Plastic Deformation Wall Thickness Reduction During Radial Minimum of 30% Expansion and Plastic Deformation Anisotropy Minimum of 1.5 Minimum Absorbed Energy at −4 F. (−20 C.) in 80 ft-lb the Longitudinal Direction Minimum Absorbed Energy at −4 F. (−20 C.) in 60 ft-lb the Transverse Direction Minimum Absorbed Energy at −4 F. (−20 C.) 60 ft-lb Transverse To A Weld Area Flare Expansion Testing Minimum of 75% Without A Failure Increase in Yield Strength Due To Radial Greater than 5.4% Expansion and Plastic Deformation

In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are characterized by an expandability coefficient f:

-   -   i. f=r×n     -   ii. where f=expandability coefficient;         -   1. r=anisotropy coefficient; and         -   2. n=strain hardening exponent.

In an exemplary embodiment, the anisotropy coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 1. In an exemplary embodiment, the strain hardening exponent for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12. In an exemplary embodiment, the expandability coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.

In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient. In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.

In several exemplary experimental embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are steel alloys having one of the following compositions: Steel Element and Percentage By Weight Alloy C Mn P S Si Cu Ni Cr A 0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02 B 0.18 1.28 0.017 0.004 0.29 0.01 0.01 0.03 C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05 D 0.02 1.31 0.02 0.001 0.45 — 9.1 18.7

In exemplary experimental embodiment, as illustrated in FIG. 20, a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YP_(BE), a yield point after radial expansion and plastic deformation of about 16% YP_(AE16%), and a yield point after radial expansion and plastic deformation of about 24% YP_(AE24%). In an exemplary experimental embodiment, YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplary experimental embodiment, the ductility of the sample of the expandable tubular member composed of Alloy A also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation: Yield Wall Point Yield Elongation Width Thickness ksi Ratio % Reduction % Reduction % Anisotropy Before 46.9 0.69 53 −52 55 0.93 Radial Expansion and Plastic Deformation After 16% 65.9 0.83 17 42 51 0.78 Radial Expansion After 24% 68.5 0.83 5 44 54 0.76 Radial Expansion % Increase 40% for 16% radial expansion 46% for 24% radial expansion

In exemplary experimental embodiment, as illustrated in FIG. 21, a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YP_(BE), a yield point after radial expansion and plastic deformation of about 16% YP_(AE16%), and a yield point after radial expansion and plastic deformation of about 24% YP_(AE24%). In an exemplary embodiment, YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplary experimental embodiment, the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation: Yield Wall Point Yield Width Thickness ksi Ratio Elongation % Reduction % Reduction % Anisotropy Before 57.8 0.71 44 43 46 0.93 Radial Expansion and Plastic Deformation After 16% 74.4 0.84 16 38 42 0.87 Radial Expansion After 24% 79.8 0.86 20 36 42 0.81 Radial Expansion % Increase 28.7% increase for 16% radial expansion 38% increase for 24% radial expansion

In an exemplary experimental embodiment, samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation: Absorbed Steel Yield Yield Elongation Ani- Energy Expandability Alloy ksi Ratio % sotropy ft-lb Coefficient A 47.6 0.71 44 1.48 145 B 57.8 0.71 44 1.04 62.2 C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 —

In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.

In an exemplary embodiment, the carbon equivalent C_(e), for tubular members having a carbon content (by weight percentage) less than or equal to 0.12%, is given by the following expression: C_(e)=C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15

where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Mn=manganese percentage by weight;

c. Cr=chromium percentage by weight;

d. Mo=molybdenum percentage by weight;

e. V=vanadium percentage by weight;

f. Ti=titanium percentage by weight;

g. Nb=niobium percentage by weight;

h. Ni=nickel percentage by weight; and

i. Cu=copper percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.

In an exemplary embodiment, the carbon equivalent C_(e), for tubular members having more than 0.12% carbon content (by weight), is given by the following expression: C_(e)=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B

-   -   where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Si=silicon percentage by weight;

c. Mn=manganese percentage by weight;

d. Cu=copper percentage by weight;

e. Cr=chromium percentage by weight;

f. Ni=nickel percentage by weight;

g. Mo=molybdenum percentage by weight;

h. V=vanadium percentage by weight; and

i. B=boron percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.36.

Referring to FIG. 22 in an exemplary embodiment, a first tubular member 2210 includes an internally threaded connection 2212 at an end portion 2214. A first end of a tubular sleeve 2216 that includes an internal flange 2218 having a tapered portion 2220, and a second end that includes a tapered portion 2222, is then mounted upon and receives the end portion 2214 of the first tubular member 2210. In an exemplary embodiment, the end portion 2214 of the first tubular member 2210 abuts one side of the internal flange 2218 of the tubular sleeve 2216, and the internal diameter of the internal flange 2218 of the tubular sleeve 2216 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210. An externally threaded connection 2224 of an end portion 2226 of a second tubular member 2228 having an annular recess 2230 is then positioned within the tubular sleeve 2216 and threadably coupled to the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210. In an exemplary embodiment, the internal flange 2218 of the tubular sleeve 2216 mates with and is received within the annular recess 2230 of the end portion 2226 of the second tubular member 2228. Thus, the tubular sleeve 2216 is coupled to and surrounds the external surfaces of the first and second tubular members, 2210 and 2228.

The internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection, and the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2216 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members, 2210 and 2228. In this manner, during the threaded coupling of the first and second tubular members, 2210 and 2228, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 22, the first and second tubular members, 2210 and 2228, and the tubular sleeve 2216 may be positioned within another structure 2232 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members. The tapered portions, 2220 and 2222, of the tubular sleeve 2216 facilitate the insertion and movement of the first and second tubular members within and through the structure 2232, and the movement of the expansion device 2234 through the interiors of the first and second tubular members, 2210 and 2228, may be, for example, from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 is also radially expanded and plastically deformed. As a result, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression.

Sleeve 2216 increases the axial compression loading of the connection between tubular members 2210 and 2228 before and after expansion by the expansion device 2234. Sleeve 2216 may, for example, be secured to tubular members 2210 and 2228 by a heat shrink fit.

In several alternative embodiments, the first and second tubular members, 2210 and 2228, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 2216 during (a) the coupling of the first tubular member 2210 to the second tubular member 2228, (b) the placement of the first and second tubular members in the structure 2232, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 2216 protects the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, during handling and insertion of the tubular members within the structure 2232. In this manner, damage to the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations. Furthermore, the tubular sleeve 2216 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 2228 to the first tubular member 2210. In this manner, misalignment that could result in damage to the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 2216 can be easily rotated, that would indicate that the first and second tubular members, 2210 and 2228, are not fully threadably coupled and in intimate contact with the internal flange 2218 of the tubular sleeve. Furthermore, the tubular sleeve 2216 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 2214 and 2226, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 2216 and the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, into the annulus between the first and second tubular members and the structure 2232. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2210 and 2228, and the tubular sleeve 2216 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 23, in an exemplary embodiment, a first tubular member 210 includes an internally threaded connection 2312 at an end portion 2314. A first end of a tubular sleeve 2316 includes an internal flange 2318 and a tapered portion 2320. A second end of the sleeve 2316 includes an internal flange 2321 and a tapered portion 2322. An externally threaded connection 2324 of an end portion 2326 of a second tubular member 2328 having an annular recess 2330, is then positioned within the tubular sleeve 2316 and threadably coupled to the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310. The internal flange 2318 of the sleeve 2316 mates with and is received within the annular recess 2330.

The first tubular member 2310 includes a recess 2331. The internal flange 2321 mates with and is received within the annular recess 2331. Thus, the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members 2310 and 2328.

The internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection, and the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2316 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members 2310 and 2328. In this manner, during the threaded coupling of the first and second tubular members 2310 and 2328, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 23, the first and second tubular members 2310 and 2328, and the tubular sleeve 2316 may then be positioned within another structure 2332 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2334 through and/or within the interiors of the first and second tubular members. The tapered portions 2320 and 2322, of the tubular sleeve 2316 facilitates the insertion and movement of the first and second tubular members within and through the structure 2332, and the displacement of the expansion device 2334 through the interiors of the first and second tubular members 2310 and 2328, may be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members 2310 and 2328, the tubular sleeve 2316 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2316 may be maintained in circumferential tension and the end portions 2314 and 2326, of the first and second tubular members 2310 and 2328, may be maintained in circumferential compression.

Sleeve 2316 increases the axial tension loading of the connection between tubular members 2310 and 2328 before and after expansion by the expansion device 2334. Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2310 and 2328, and the tubular sleeve 2316 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 24, in an exemplary embodiment, a first tubular member 2410 includes an internally threaded connection 2412 at an end portion 2414. A first end of a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion 2420. A second end of the sleeve 2416 includes an internal flange 2421 and a tapered portion 2422. An externally threaded connection 2424 of an end portion 2426 of a second tubular member 2428 having an annular recess 2430, is then positioned within the tubular sleeve 2416 and threadably coupled to the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410. The internal flange 2418 of the sleeve 2416 mates with and is received within the annular recess 2430. The first tubular member 2410 includes a recess 2431. The internal flange 2421 mates with and is received within the annular recess 2431. Thus, the sleeve 2416 is coupled to and surrounds the external surfaces of the first and second tubular members 2410 and 2428.

The internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection, and the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2416 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members 2410 and 2428. In this manner, during the threaded coupling of the first and second tubular members 2410 and 2428, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 24, the first and second tubular members 2410 and 2428, and the tubular sleeve 2416 may then be positioned within another structure 2432 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2434 through and/or within the interiors of the first and second tubular members. The tapered portions 2420 and 2422, of the tubular sleeve 2416 facilitate the insertion and movement of the first and second tubular members within and through the structure 2432, and the displacement of the expansion device 2434 through the interiors of the first and second tubular members, 2410 and 2428, may be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members, 2410 and 2428, the tubular sleeve 2416 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2416 may be maintained in circumferential tension and the end portions, 2414 and 2426, of the first and second tubular members, 2410 and 2428, may be maintained in circumferential compression.

The sleeve 2416 increases the axial compression and tension loading of the connection between tubular members 2410 and 2428 before and after expansion by expansion device 2424. Sleeve 2416 may be secured to tubular members 2410 and 2428 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2410 and 2428, and the tubular sleeve 2416 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 25, in an exemplary embodiment, a first tubular member 2510 includes an internally threaded connection 2512 at an end portion 2514. A first end of a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520. A second end of the sleeve 2516 includes an internal flange 2521 and a relief 2522. An externally threaded connection 2524 of an end portion 2526 of a second tubular member 2528 having an annular recess 2530, is then positioned within the tubular sleeve 2516 and threadably coupled to the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510. The internal flange 2518 of the sleeve 2516 mates with and is received within the annular recess 2530. The first tubular member 2510 includes a recess 2531. The internal flange 2521 mates with and is received within the annular recess 2531. Thus, the sleeve 2516 is coupled to and surrounds the external surfaces of the first and second tubular members 2510 and 2528.

The internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection, and the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2516 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members 2510 and 2528. In this manner, during the threaded coupling of the first and second tubular members 2510 and 2528, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 25, the first and second tubular members 2510 and 2528, and the tubular sleeve 2516 may then be positioned within another structure 2532 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2534 through and/or within the interiors of the first and second tubular members. The reliefs 2520 and 2522 are each filled with a sacrificial material 2540 including a tapered surface 2542 and 2544, respectively. The material 2540 may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2510 and 2528, through the structure 2532. The displacement of the expansion device 2534 through the interiors of the first and second tubular members 2510 and 2528, may, for example, be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members 2510 and 2528, the tubular sleeve 2516 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2516 may be maintained in circumferential tension and the end portions 2514 and 2526, of the first and second tubular members, 2510 and 2528, may be maintained in circumferential compression.

The addition of the sacrificial material 2540, provided on sleeve 2516, avoids stress risers on the sleeve 2516 and the tubular member 2510. The tapered surfaces 2542 and 2544 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2516. Sleeve 2516 may be secured to tubular members 2510 and 2528 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2510 and 2528, and the tubular sleeve 2516 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 26, in an exemplary embodiment, a first tubular member 2610 includes an internally threaded connection 2612 at an end portion 2614. A first end of a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion 2620. A second end of the sleeve 2616 includes an internal flange 2621 and a tapered portion 2622. An externally threaded connection 2624 of an end portion 2626 of a second tubular member 2628 having an annular recess 2630, is then positioned within the tubular sleeve 2616 and threadably coupled to the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610. The internal flange 2618 of the sleeve 2616 mates with and is received within the annular recess 2630.

The first tubular member 2610 includes a recess 2631. The internal flange 2621 mates with and is received within the annular recess 2631. Thus, the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members 2610 and 2628.

The internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection, and the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2616 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members 2610 and 2628. In this manner, during the threaded coupling of the first and second tubular members 2610 and 2628, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 26, the first and second tubular members 2610 and 2628, and the tubular sleeve 2616 may then be positioned within another structure 2632 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2634 through and/or within the interiors of the first and second tubular members. The tapered portions 2620 and 2622, of the tubular sleeve 2616 facilitates the insertion and movement of the first and second tubular members within and through the structure 2632, and the displacement of the expansion device 2634 through the interiors of the first and second tubular members 2610 and 2628, may, for example, be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members 2610 and 2628, the tubular sleeve 2616 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2616 may be maintained in circumferential tension and the end portions 2614 and 2626, of the first and second tubular members 2610 and 2628, may be maintained in circumferential compression.

Sleeve 2616 is covered by a thin walled cylinder of sacrificial material 2640. Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622, respectively, are also filled with an excess of the sacrificial material 2640. The material may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2610 and 2628, through the structure 2632.

The addition of the sacrificial material 2640, provided on sleeve 2616, avoids stress risers on the sleeve 2616 and the tubular member 2610. The excess of the sacrificial material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2616. Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2610 and 2628, and the tubular sleeve 2616 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 27, in an exemplary embodiment, a first tubular member 2710 includes an internally threaded connection 2712 at an end portion 2714. A first end of a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion 2720. A second end of the sleeve 2716 includes an internal flange 2721 and a tapered portion 2722. An externally threaded connection 2724 of an end portion 2726 of a second tubular member 2728 having an annular recess 2730, is then positioned within the tubular sleeve 2716 and threadably coupled to the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710. The internal flange 2718 of the sleeve 2716 mates with and is received within the annular recess 2730.

The first tubular member 2710 includes a recess 2731. The internal flange 2721 mates with and is received within the annular recess 2731. Thus, the sleeve 2716 is coupled to and surrounds the external surfaces of the first and second tubular members 2710 and 2728.

The internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 is a box connection, and the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2716 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members 2710 and 2728. In this manner, during the threaded coupling of the first and second tubular members 2710 and 2728, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 27, the first and second tubular members 2710 and 2728, and the tubular sleeve 2716 may then be positioned within another structure 2732 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2734 through and/or within the interiors of the first and second tubular members. The tapered portions 2720 and 2722, of the tubular sleeve 2716 facilitates the insertion and movement of the first and second tubular members within and through the structure 2732, and the displacement of the expansion device 2734 through the interiors of the first and second tubular members 2710 and 2728, may be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members 2710 and 2728, the tubular sleeve 2716 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2716 may be maintained in circumferential tension and the end portions 2714 and 2726, of the first and second tubular members 2710 and 2728, may be maintained in circumferential compression.

Sleeve 2716 has a variable thickness due to one or more reduced thickness portions 2790 and/or increased thickness portions 2792.

Varying the thickness of sleeve 2716 provides the ability to control or induce stresses at selected positions along the length of sleeve 2716 and the end portions 2724 and 2726. Sleeve 2716 may be secured to tubular members 2710 and 2728 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2710 and 2728, and the tubular sleeve 2716 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 28, in an alternative embodiment, instead of varying the thickness of sleeve 2716, the same result described above with reference to FIG. 27, may be achieved by adding a member 2740 which may be coiled onto the grooves 2739 formed in sleeve 2716, thus varying the thickness along the length of sleeve 2716.

Referring to FIG. 29, in an exemplary embodiment, a first tubular member 2910. includes an internally threaded connection 2912 and an internal annular recess 2914 at an end portion 2916. A first end of a tubular sleeve 2918 includes an internal flange 2920, and a second end of the sleeve 2916 mates with and receives the end portion 2916 of the first tubular member 2910. An externally threaded connection 2922 of an end portion 2924 of a second tubular member 2926 having an annular recess 2928, is then positioned within the tubular sleeve 2918 and threadably coupled to the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910. The internal flange 2920 of the sleeve 2918 mates with and is received within the annular recess 2928. A sealing element 2930 is received within the internal annular recess 2914 of the end portion 2916 of the first tubular member 2910.

The internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 is a box connection, and the externally threaded connection 2922 of the end portion 2924 of the second tubular member 2926 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2918 is at least approximately 0.020″ greater than the outside diameters of the first tubular member 2910. In this manner, during the threaded coupling of the first and second tubular members 2910 and 2926, fluidic materials within the first and second tubular members may be vented from the tubular members.

The first and second tubular members 2910 and 2926, and the tubular sleeve 2918 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, the tubular sleeve 2918 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2918 may be maintained in circumferential tension and the end portions 2916 and 2924, of the first and second tubular members 2910 and 2926, respectively, may be maintained in circumferential compression.

In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, the sealing element 2930 seals the interface between the first and second tubular members. In an exemplary embodiment, during and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, a metal to metal seal is formed between at least one of: the first and second tubular members 2910 and 2926, the first tubular member and the tubular sleeve 2918, and/or the second tubular member and the tubular sleeve. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.

In several exemplary embodiments, one or more portions of the first and second tubular members, 2910 and 2926, the tubular sleeve 2918, and the sealing element 2930 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 a, in an exemplary embodiment, a first tubular member 3010 includes internally threaded connections 3012 a and 3012 b, spaced apart by a cylindrical internal surface 3014, at an end portion 3016. Externally threaded connections 3018 a and 3018 b, spaced apart by a cylindrical external surface 3020, of an end portion 3022 of a second tubular member 3024 are threadably coupled to the internally threaded connections, 3012 a and 3012 b, respectively, of the end portion 3016 of the first tubular member 3010. A sealing element 3026 is received within an annulus defined between the internal cylindrical surface 3014 of the first tubular member 3010 and the external cylindrical surface 3020 of the second tubular member 3024.

The internally threaded connections, 3012 a and 3012 b, of the end portion 3016 of the first tubular member 3010 are box connections, and the externally threaded connections, 3018 a and 3018 b, of the end portion 3022 of the second tubular member 3024 are pin connections. In an exemplary embodiment, the sealing element 3026 is an elastomeric and/or metallic sealing element.

The first and second tubular members 3010 and 3024 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.

In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, the sealing element 3026 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between at least one of: the first and second tubular members 3010 and 3024, the first tubular member and the sealing element 3026, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.

In an alternative embodiment, the sealing element 3026 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3010 and 3024, the sealing element 3026 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 b, in an exemplary embodiment, a first tubular member 3030 includes internally threaded connections 3032 a and 3032 b, spaced apart by an undulating approximately cylindrical internal surface 3034, at an end portion 3036. Externally threaded connections 3038 a and 3038 b, spaced apart by a cylindrical external surface 3040, of an end portion 3042 of a second tubular member 3044 are threadably coupled to the internally threaded connections, 3032 a and 3032 b, respectively, of the end portion 3036 of the first tubular member 3030. A sealing element 3046 is received within an annulus defined between the undulating approximately cylindrical internal surface 3034 of the first tubular member 3030 and the external cylindrical surface 3040 of the second tubular member 3044.

The internally threaded connections, 3032 a and 3032 b, of the end portion 3036 of the first tubular member 3030 are box connections, and the externally threaded connections, 3038 a and 3038 b, of the end portion 3042 of the second tubular member 3044 are pin connections. In an exemplary embodiment, the sealing element 3046 is an elastomeric and/or metallic sealing element.

The first and second tubular members 3030 and 3044 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.

In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, the sealing element 3046 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between at least one of: the first and second tubular members 3030 and 3044, the first tubular member and the sealing element 3046, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.

In an alternative embodiment, the sealing element 3046 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3030 and 3044, the sealing element 3046 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 c, in an exemplary embodiment, a first tubular member 3050 includes internally threaded connections 3052 a and 3052 b, spaced apart by a cylindrical internal surface 3054 including one or more square grooves 3056, at an end portion 3058. Externally threaded connections 3060 a and 3060 b, spaced apart by a cylindrical external surface 3062 including one or more square grooves 3064, of an end portion 3066 of a second tubular member 3068 are threadably coupled to the internally threaded connections, 3052 a and 3052 b, respectively, of the end portion 3058 of the first tubular member 3050. A sealing element 3070 is received within an annulus defined between the cylindrical internal surface 3054 of the first tubular member 3050 and the external cylindrical surface 3062 of the second tubular member 3068.

The internally threaded connections, 3052 a and 3052 b, of the end portion 3058 of the first tubular member 3050 are box connections, and the externally threaded connections, 3060 a and 3060 b, of the end portion 3066 of the second tubular member 3068 are pin connections. In an exemplary embodiment, the sealing element 3070 is an elastomeric and/or metallic sealing element.

The first and second tubular members 3050 and 3068 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.

In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3050 and 3068, the sealing element 3070 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members, 3050 and 3068, a metal to metal seal is formed between at least one of: the first and second tubular members, the first tubular member and the sealing element 3070, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.

In an alternative embodiment, the sealing element 3070 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 950 and 968, a metal to metal seal is formed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3050 and 3068, the sealing element 3070 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 31, in an exemplary embodiment, a first tubular member 3110 includes internally threaded connections, 3112 a and 3112 b, spaced apart by a non-threaded internal surface 3114, at an end portion 3116. Externally threaded connections, 3118 a and 3118 b, spaced apart by a non-threaded external surface 3120, of an end portion 3122 of a second tubular member 3124 are threadably coupled to the internally threaded connections, 3112 a and 3112 b, respectively, of the end portion 3122 of the first tubular member 3124.

First, second, and/or third tubular sleeves, 3126, 3128, and 3130, are coupled the external surface of the first tubular member 3110 in opposing relation to the threaded connection formed by the internal and external threads, 3112 a and 3118 a, the interface between the non-threaded surfaces, 3114 and 3120, and the threaded connection formed by the internal and external threads, 3112 b and 3118 b, respectively.

The internally threaded connections, 3112 a and 3112 b, of the end portion 3116 of the first tubular member 3110 are box connections, and the externally threaded connections, 3118 a and 3118 b, of the end portion 3122 of the second tubular member 3124 are pin connections.

The first and second tubular members 3110 and 3124, and the tubular sleeves 3126, 3128, and/or 3130, may then be positioned within another structure 3132 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 3134 through and/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first and second tubular members 3110 and 3124, the tubular sleeves 3126, 3128 and/or 3130 are also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeves 3126, 3128, and/or 3130 are maintained in circumferential tension and the end portions 3116 and 3122, of the first and second tubular members 3110 and 3124, may be maintained in circumferential compression.

The sleeves 3126, 3128, and/or 3130 may, for example, be secured to the first tubular member 3110 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and 3130, have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 32 a, in an exemplary embodiment, a first tubular member 3210 includes an internally threaded connection 3212 at an end portion 3214. An externally threaded connection 3216 of an end portion 3218 of a second tubular member 3220 are threadably coupled to the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210.

The internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection, and the externally threaded connection 3216 of the end portion 3218 of the second tubular member 3220 is a pin connection.

A tubular sleeve 3222 including internal flanges 3224 and 3226 is positioned proximate and surrounding the end portion 3214 of the first tubular member 3210. As illustrated in FIG. 32 b, the tubular sleeve 3222 is then forced into engagement with the external surface of the end portion 3214 of the first tubular member 3210 in a conventional manner. As a result, the end portions, 3214 and 3218, of the first and second tubular members, 3210 and 3220, are upset in an undulating fashion.

The first and second tubular members 3210 and 3220, and the tubular sleeve 3222, may then be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first and second tubular members 3210 and 3220, the tubular sleeve 3222 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 3222 is maintained in circumferential tension and the end portions 3214 and 3218, of the first and second tubular members 3210 and 3220, may be maintained in circumferential compression.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3210 and 3220, and the sleeve 3222 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 33, in an exemplary embodiment, a first tubular member 3310 includes an internally threaded connection 3312 and an annular projection 3314 at an end portion 3316.

A first end of a tubular sleeve 3318 that includes an internal flange 3320 having a tapered portion 3322 and an annular recess 3324 for receiving the annular projection 3314 of the first tubular member 3310, and a second end that includes a tapered portion 3326, is then mounted upon and receives the end portion 3316 of the first tubular member 3310.

In an exemplary embodiment, the end portion 3316 of the first tubular member 3310 abuts one side of the internal flange 3320 of the tubular sleeve 3318 and the annular projection 3314 of the end portion of the first tubular member mates with and is received within the annular recess 3324 of the internal flange of the tubular sleeve, and the internal diameter of the internal flange 3320 of the tubular sleeve 3318 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310. An externally threaded connection 3326 of an end portion 3328 of a second tubular member 3330 having an annular recess 3332 is then positioned within the tubular sleeve 3318 and threadably coupled to the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310. In an exemplary embodiment, the internal flange 3332 of the tubular sleeve 3318 mates with and is received within the annular recess 3332 of the end portion 3328 of the second tubular member 3330. Thus, the tubular sleeve 3318 is coupled to and surrounds the external surfaces of the first and second tubular members, 3310 and 3328.

The internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 is a box connection, and the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 3318 is at least approximately 0.020″ greater than the outside diameters of the first and second tubular members, 3310 and 3330. In this manner, during the threaded coupling of the first and second tubular members, 3310 and 3330, fluidic materials within the first and second tubular members may be vented from the tubular members.

As illustrated in FIG. 33, the first and second tubular members, 3310 and 3330, and the tubular sleeve 3318 may be positioned within another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members. The tapered portions, 3322 and 3326, of the tubular sleeve 3318 facilitate the insertion and movement of the first and second tubular members within and through the structure 3334, and the movement of the expansion device 3336 through the interiors of the first and second tubular members, 3310 and 3330, may, for example, be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression.

Sleeve 3316 increases the axial compression loading of the connection between tubular members 3310 and 3330 before and after expansion by the expansion device 3336. Sleeve 3316 may be secured to tubular members 3310 and 3330, for example, by a heat shrink fit.

In several alternative embodiments, the first and second tubular members, 3310 and 3330, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3318 during (a) the coupling of the first tubular member 3310 to the second tubular member 3330, (b) the placement of the first and second tubular members in the structure 3334, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 3318 protects the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, during handling and insertion of the tubular members within the structure 3334. In this manner, damage to the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations. Furthermore, the tubular sleeve 3318 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3330 to the first tubular member 3310. In this manner, misalignment that could result in damage to the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3318 can be easily rotated, that would indicate that the first and second tubular members, 3310 and 3330, are not fully threadably coupled and in intimate contact with the internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve 3318 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3316 and 3328, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 3318 and the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, into the annulus between the first and second tubular members and the structure 3334. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first and second tubular members, 3310 and 3330, and the sleeve 3318 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIGS. 34 a, 34 b, and 34 c, in an exemplary embodiment, a first tubular member 3410 includes an internally threaded connection 1312 and one or more external grooves 3414 at an end portion 3416.

A first end of a tubular sleeve 3418 that includes an internal flange 3420 and a tapered portion 3422, a second end that includes a tapered portion 3424, and an intermediate portion that includes one or more longitudinally aligned openings 3426, is then mounted upon and receives the end portion 3416 of the first tubular member 3410.

In an exemplary embodiment, the end portion 3416 of the first tubular member 3410 abuts one side of the internal flange 3420 of the tubular sleeve 3418, and the internal diameter of the internal flange 3420 of the tubular sleeve 3416 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410. An externally threaded connection 3428 of an end portion 3430 of a second tubular member 3432 that includes one or more internal grooves 3434 is then positioned within the tubular sleeve 3418 and threadably coupled to the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410. In an exemplary embodiment, the internal flange 3420 of the tubular sleeve 3418 mates with and is received within an annular recess 3436 defined in the end portion 3430 of the second tubular member 3432. Thus, the tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432.

The first and second tubular members, 3410 and 3432, and the tubular sleeve 3418 may be positioned within another structure such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device within and/or through the interiors of the first and second tubular members. The tapered portions, 3422 and 3424, of the tubular sleeve 3418 facilitate the insertion and movement of the first and second tubular members within and through the structure, and the movement of the expansion device through the interiors of the first and second tubular members, 3410 and 3432, may be from top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 3418 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression.

Sleeve 3416 increases the axial compression loading of the connection between tubular members 3410 and 3432 before and after expansion by the expansion device. The sleeve 3418 may be secured to tubular members 3410 and 3432, for example, by a heat shrink fit.

During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the grooves 3414 and/or 3434 and/or the openings 3426 provide stress concentrations that in turn apply added stress forces to the mating threads of the threaded connections, 3412 and 3428. As a result, during and after the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the mating threads of the threaded connections, 3412 and 3428, are maintained in metal to metal contact thereby providing a fluid and gas tight connection. In an exemplary embodiment, the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another. In an exemplary embodiment, the grooves 3414 and/or 3434 are helical grooves.

In several alternative embodiments, the first and second tubular members, 3410 and 3432, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3418 during (a) the coupling of the first tubular member 3410 to the second tubular member 3432, (b) the placement of the first and second tubular members in the structure, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 3418 protects the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, during handling and insertion of the tubular members within the structure. In this manner, damage to the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations. Furthermore, the tubular sleeve 3418 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3432 to the first tubular member 3410. In this manner, misalignment that could result in damage to the threaded connections, 3412 and 3428, of the first and second tubular members, 3410 and 3432, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 3416 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3418 can be easily rotated, that would indicate that the first and second tubular members, 3410 and 3432, are not fully threadably coupled and in intimate contact with the internal flange 3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3416 and 3430, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 3418 may provide a fluid and gas tight metal-to-metal seal between interior surface of the tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3412 and 3430, of the first and second tubular members, 3410 and 3432, into the annulus between the first and second tubular members and the structure. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.

In several exemplary embodiments, the first and second tubular members described above with reference to FIGS. 1 to 34 c are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: The present application is related to the following: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18/2000, (21) U.S. provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20/2001, (23) U.S. provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (25) U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26) U.S. provisional patent application Ser. No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, (28) U.S. provisional patent application Ser. No. 60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (29) U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (30) U.S. utility patent application Ser. No. 10/016,467, attorney docket no. 25791.70, filed on Dec. 10, 2001, (31) U.S. provisional patent application Ser. No. 60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001; and (32) U.S. provisional patent application Ser. No. 60/346,309, attorney docket no. 25791.92, filed on Jan. 07, 2002, the disclosures of which are incorporated herein by reference.

Referring to FIG. 35 a an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504. In an exemplary embodiment, the material properties of the first and second tubular regions, 3502 and 3504, are different. In an exemplary embodiment, the yield points of the first and second tubular regions, 3502 and 3504, are different. In an exemplary embodiment, the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504. In several exemplary embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member 3500.

Referring to FIG. 35 b, in an exemplary embodiment, the yield point within the first and second tubular regions, 3502 a and 3502 b, of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member. In an exemplary embodiment, the yield point increases as a function of the radial position within the expandable tubular member 3502. In an exemplary embodiment, the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship. In an exemplary embodiment, the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship. In an exemplary embodiment, the yield point increases at different rates within the first and second tubular regions, 3502 a and 3502 b, as a function of the radial position within the expandable tubular member 3502. In an exemplary embodiment, the functional relationship, and value, of the yield points within the first and second tubular regions, 3502 a and 3502 b, of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.

In several exemplary embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, prior to a radial expansion and plastic deformation, include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite. In this manner, the hard phase provides high strength, the soft phase provides ductility, and the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation. Furthermore, in this manner, the yield point of the tubular member increases as a result of the radial expansion and plastic deformation. Further, in this manner, the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation. In an exemplary embodiment, the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.

In an exemplary experimental embodiment, as illustrated in FIGS. 36 a-36 c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed in accordance with a method 3600, in which, in step 3602, an expandable tubular member 3602 a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3602 a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 36 b, in step 3602, the expandable tubular member 3602 a includes a microstructure that includes martensite, pearlite, and V, Ni, and/or Ti carbides.

In an exemplary embodiment, the expandable tubular member 3602 a is then heated at a temperature of 790° C. for about 10 minutes in step 3604.

In an exemplary embodiment, the expandable tubular member 3602 a is then quenched in water in step 3606.

In an exemplary experimental embodiment, as illustrated in FIG. 36 c, following the completion of step 3606, the expandable tubular member 3602 a includes a microstructure that includes new ferrite, grain pearlite, martensite, and ferrite. In an exemplary experimental embodiment, following the completion of step 3606, the expandable tubular member 3602 a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.

In an exemplary embodiment, the expandable tubular member 3602 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3602 a, the yield strength of the expandable tubular member is about 95 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 37 a-37 c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed in accordance with a method 3700, in which, in step 3702, an expandable tubular member 3702 a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3702 a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 37 b, in step 3702, the expandable tubular member 3702 a includes a microstructure that includes pearlite and pearlite striation.

In an exemplary embodiment, the expandable tubular member 3702 a is then heated at a temperature of 790° C. for about 10 minutes in step 3704.

In an exemplary embodiment, the expandable tubular member 3702 a is then quenched in water in step 3706.

In an exemplary experimental embodiment, as illustrated in FIG. 37 c, following the completion of step 3706, the expandable tubular member 3702 a includes a microstructure that includes ferrite, martensite, and bainite. In an exemplary experimental embodiment, following the completion of step 3706, the expandable tubular member 3702 a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.

In an exemplary embodiment, the expandable tubular member 3702 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3702 a, the yield strength of the expandable tubular member is about 130 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 38 a-38 c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed in accordance with a method 3800, in which, in step 3802, an expandable tubular member 3802 a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3802 a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 38 b, in step 3802, the expandable tubular member 3802 a includes a microstructure that includes grain pearlite, widmanstatten martensite and carbides of V, Ni, and/or Ti.

In an exemplary embodiment, the expandable tubular member 3802 a is then heated at a temperature of 790° C. for about 10 minutes in step 3804.

In an exemplary embodiment, the expandable tubular member 3802 a is then quenched in water in step 3806.

In an exemplary experimental embodiment, as illustrated in FIG. 38 c, following the completion of step 3806, the expandable tubular member 3802 a includes a microstructure that includes bainite, pearlite, and new ferrite. In an exemplary experimental embodiment, following the completion of step 3806, the expandable tubular member 3802 a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.

In an exemplary embodiment, the expandable tubular member 3802 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3802 a, the yield strength of the expandable tubular member is about 97 ksi.

Referring now to FIG. 39, a method for manufacturing an expandable tubular member 3900 is illustrated. The method 3900 begins at step 3902 with providing a tubular member. In an exemplary embodiment, the tubular member may be any conventional tubular member or any conventional connection for expandable tubular members. At step 3904, the tubular member is given a heat treatment using methods known in the art. At step 3906, the tubular member is then quenched and, in step 3908, the tubular member is cold worked. In an exemplary embodiment, the tubular member is an X-52-1 pipe, with a chemical composition, by weight percentage, of 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, 0.05% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti, and is quenched in water at approximately 705° C., resulting in a tensile strength of 94 ksi and a yield strength of 56 ksi. In an exemplary embodiment, the tubular member is a JFE-A-1 pipe, with a chemical composition, by weight percentage, of 0.065% C, 1.44% MN, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti, and is quenched in water at approximately 790° C., resulting in a tensile strength of 94 ksi and a yield strength of 59 ksi. In an exemplary embodiment, the tubular member is a JFE-B-1 pipe, with a chemical composition, by weight percentage, of 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti, and is quenched in water at approximately 735° C., resulting in a tensile strength of 94 ksi and a yield strength of 56 ksi. In an exemplary embodiment, the tubular member is an X-52-2 pipe, with a chemical composition, by weight percentage, of 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, 0.05% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti, and is quenched in oil at approximately 775° C., resulting in a tensile strength of 84 ksi and a yield strength of 49 ksi. In an exemplary embodiment, the tubular member is a JFE-A-2 pipe, with a chemical composition, by weight percentage, of 0.065% C, 1.44% MN, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti, and is quenched in oil at approximately 820° C., resulting in a tensile strength of 92 ksi and a yield strength of 61 ksi. In an exemplary embodiment, the tubular member is a JFE-B-2 pipe, with a chemical composition, by weight percentage, of 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti, and is quenched in oil at approximately 750° C., resulting in a tensile strength of 109 ksi and a yield strength of 58 ksi. In an exemplary embodiment, an expandable tubular member processed by the method 3900 may, upon radial expansion, achieve an increased yield strength.

Referring now to FIG. 40, a method for expanding an expandable tubular member is illustrated. The method 4000 begins at step 4002 where a tubular member is provided. In an exemplary embodiment, the tubular member provided is manufactured by the method 3900 of FIG. 39. At step 4004, the tubular member is lubricated, and in step 4006, the tubular member is expanded. In an exemplary embodiment, the lubricant is a EGT MS-9075, commercially available from Brighton Inc., which results in a coefficient of friction of 0.125 and a required expansion force of approximately 146000 lbs. In an exemplary embodiment, the lubricant is a EGT MS-9075, commercially available from Brighton Inc., which results in a coefficient of friction of 0.075 and a required expansion force of approximately 143000 lbs. In an exemplary embodiment, the lubricant is a Brighton lubricant, commercially available from Brighton Inc., with grease which results in a coefficient of friction of 0.02 and a required expansion force of approximately 150000 lbs. In an exemplary embodiment, the lubricant is EGT MS-9075 lubricant, commercially available from Brighton Inc., used on a 55 ksi steel which results in a coefficient of friction of 0.02 and a required expansion force of approximately 126000 lbs. In an exemplary embodiment, the lubricant is EGT MS-9075 lubricant, commercially available from Brighton Inc., used on a steel pipe with a 55 ksi yield strength before pipe expansion and a 100 ksi yield strength after expansion which results in a coefficient of friction of 0.02 and a required expansion force of approximately 127000 lbs. In an exemplary embodiment, the lubrication of the tubular member decreases the force needed to expand the tubular member, allowing a thicker pipe to be used for the same expansion force, resulting in a higher collapse strength.

Referring now to FIG. 41, a method 4100 for formability evaluation for a material suitable for expandable tubular members is illustrated including a plurality of parameters. A stress-strain properties parameter 4102 is used to determine the optimum combination of the strength and elongation for the material. A Charpy V-notch impact value parameter 4104 is used to predict the likelihood of brittle fracture for the material. A stress rupture parameter 4106 is used and may include a burst and collapse value which should be optimized considering higher strength against decreased ductility with increased susceptibility to environmental cracking. A strain-hardening exponent parameter 4108 is used to find higher values such that the material should not fail during radial expansion. A plastic strain ratio 4110 is determined by comparing the strains in the width and thickness direction and used to find ratios 4110 greater than 1 indicating materials which are good for manufacturing an expandable tubular member such as, for example, through the method 4000 illustrated in FIG. 40.

In an exemplary experimental embodiment, as illustrated in FIG. 42, an expandable tubular member 4200 may be provided using, for example, the method 3900 illustrated in FIG. 39, with a minimum flare expansion of 45%, a tensile strength of 60-120 ksi, a yield strength of 40-100 ksi, a yield strength to tensile strength ratio of 50-85%, an minimum elongation change due to radial expansion of 35%, a minimum width reduction due to radial expansion of 40%, a minimum thickness reduction due to radial expansion of 30%, and a minimum anisotropy of 1.5. In an exemplary embodiment, the absorbed energy of the expandable tubular member 4200 at negative 4 degrees Fahrenheit is 80 ft-lb in a longitudinal direction, 60 ft-lb in a transverse direction, and 60 ft-lb in a transverse weld area.

In an exemplary experimental embodiment, as illustrated in FIG. 43, a method 4300 is provided for transforming the yield strength of an expandable tubular member. In an exemplary embodiment, the expandable tubular member includes a dual-phase steel composition including, by weight percentage, 0.12% C, 0.4% Si, 1.5% Mn, and 0.02% Nb. The manufactured tubular member 4302 includes a yield strength of approximately 50 ksi. After cold rolling at 4304, the yield strength of the expandable tubular member 4300 increases to approximately 120 ksi. The expandable tubular member 4300 is then annealed at 4306, reducing its yield strength to approximately 35 ksi. The expandable tubular member 4300 may then be radially expanded at 4308, increasing the yield strength to approximately 90 ksi. Baking at 4310 will further increase the yield strength of the expandable tubular member 4300 to approximately 100 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 44, an expandable tubular member 4400 may be provided using, for example, the method 3900 illustrated in FIG. 39, with a minimum flare expansion of 45%, a tensile strength of 60-100 ksi, a yield strength of 60-90 ksi, a maximum yield strength to tensile strength ratio of 85%, an minimum elongation change due to radial expansion of 22%, a minimum width reduction due to radial expansion of 30%, a minimum thickness reduction due to radial expansion of 35%, and a minimum anisotropy of 0.5. In an exemplary embodiment, the absorbed energy of the expandable tubular member 4200 at negative 4 degrees Fahrenheit is 80 ft-lb in a longitudinal direction, 60 ft-lb in a transverse direction, and 60 ft-lb in a transverse weld area.

In an exemplary experimental embodiment, as illustrated in FIG. 45, an expandable tubular member 4500 may be provided using, for example, the method 3900 illustrated in FIG. 39, with a minimum flare expansion of 75%, a tensile strength of 60-120 ksi, a yield strength of 40-100 ksi, a yield strength to tensile strength ratio of 50-85%, an minimum elongation change due to radial expansion of 35%, a minimum width reduction due to radial expansion of 40%, a minimum thickness reduction due to radial expansion of 30%, and a minimum anisotropy of 1.5. In an exemplary embodiment, the absorbed energy of the expandable tubular member 4200 at negative 4 degrees Fahrenheit is 80 ft-lb in a longitudinal direction, 60 ft-lb in a transverse direction, and 60 ft-lb in a transverse weld area.

In an exemplary experimental embodiment, as illustrated in FIG. 46, a method 4600 is provided for transforming the yield strength of an expandable tubular member 4602. The expandable tubular member 4602 includes a yield strength of approximately 70 ksi. The expandable tubular member 4602 may then be annealed at 4604, reducing its yield strength to approximately 30 ksi. The expandable tubular member 4602 may then be expanded at 4606, increasing the yield strength to approximately 90 ksi. Baking at 4608 may further increase the yield strength of the expandable tubular member 4602 to approximately 100 ksi. In an exemplary embodiment, the cold rolling in step 4304 may be omitted.

In an exemplary experimental embodiment, as illustrated in FIG. 47, an expandable tubular member 4700 may be provided using, for example, the method 3900 illustrated in FIG. 39, including a yield strength of approximately 77 ksi, a tensile strength of approximately 83 ksi, and an elongation change due to radial expansion of 32%. In several exemplary embodiments, the tubular member 4700 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1 or JFE-B-2 tubulars described above.

In an exemplary embodiment, as illustrated in FIG. 48, an expansion device 4800 includes a textured external surface 4802 having a self lubricating hard coating 4804 applied onto the external surface. A self lubricating soft coating/film grease and lubricated mud 4806 may also be applied onto the external surface 4802, alone, or in combination with the lubricating hard coating 4804. In an exemplary embodiment, the application of the lubricant coatings 4804 and 4806 result in a friction coefficient of not more than 0.05, and the lubricant coating 4806 may withstand abrasive and corrosive environment, while the lubricant 4804 may withstand multiple expansions and abrasive and corrosive environments.

In an exemplary experimental embodiment, as illustrated in FIG. 49, a force of approximately 140000 lbs was required to radially expand an expandable tubular member 4902 with a coefficient of friction greater than about 0.100 during the radial expansion process. In another exemplary experimental embodiment, a force of approximately 118000 lbs was require to radially expand an expandable tubular member 4904 with a coefficient of friction between about 0.05 and 0.075 during the radial expansion process. In several exemplary embodiments, the tubular members 4902 and 4904 may be one or more of X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1 or JFE-B-2 tubulars described above.

In an exemplary embodiment, as illustrated in FIGS. 50 a and 50 b, an expandable tubular member 5000 may be provided using, for example, the method 3900 illustrated in FIG. 39, which includes a yield strength in the range of 40 ksi to 80 ksi, a maximum yield to tensile ratio of less than 0.5, an elongation 5006 of greater than 30%, a minimum width reduction due to radial expansion of greater than 45%, a minimum wall thickness reduction due to radial expansion of greater than 30%, and a minimum anisotropy of greater than 1.5. In several exemplary embodiments, the tubular member 5000 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1 or JFE-B-2 tubulars described above.

In an exemplary experimental embodiment, as illustrated in FIG. 51, radial expansion of an expandable tubular member 5100 required a load of approximately 150000 lbs. In an exemplary experimental embodiment, radial expansion of an expandable tubular member 5102 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., required a load of approximately 125000 lbs. In an exemplary experimental embodiment, radial expansion of an expandable tubular member 5104 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., and a grease lubricant coating required a load of approximately 95000 lbs. In an exemplary embodiment, radial expansion of an expandable tubular member 5106 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., and a grease lubricant coating required a load of approximately 80000 lbs. In an exemplary embodiment, the expandable tubular members 5102, 5104, and 5106 may be expanded using the method 4000 illustrated in FIG. 40. In several exemplary embodiments, the tubular members, 5102, 5104, and/or 5106, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1 or JFE-B-2 tubulars described above.

In an exemplary experimental embodiment, as illustrated in FIG. 52, an expandable tubular member 5200 including a Brighton BSFL lubricant coating, commercially available from Brighton Inc., resulted in a friction coefficient of 0.125, a required radial expansion force of approximately 146000 lbs, a wall thickness of 0.305, a diameter to thickness ratio of 24.8, and a collapse strength of approximately 2400 ksi. In an exemplary experimental embodiment, an expandable tubular member 5202 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., resulted in a friction coefficient of 0.075, a required expansion force of approximately 143000 lbs, a wall thickness of 0.350, a diameter to thickness ratio of 21.6, and a collapse strength of approximately 3250 ksi. In an exemplary experimental embodiment, an expandable tubular member 5204 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., and grease lubricant coating resulted in a friction coefficient of 0.02, a required expansion force of approximately 150000 lbs, a wall thickness of 0.450, a diameter to thickness ratio of 16.8, and a collapse strength of approximately 5800 ksi. In an exemplary experimental embodiment, an expandable tubular member 5206 including a 55 ksi steel and EGT MS-9075 lubricant coating, commercially available from Brighton Inc., and grease lubricant coating resulted in a friction coefficient of 0.02, a required expansion force of approximately 126000 lbs, a wall thickness of 0.500, a diameter to thickness ratio of 15.1, and a collapse strength of approximately 5350 ksi. In an exemplary experimental embodiment, an expandable tubular member 5208 including EGT MS-9075 lubricant coating, commercially available from Brighton Inc., resulted in a friction coefficient of 0.02, a required expansion force of approximately 127000 lbs, a wall thickness of 0.500, a diameter to thickness ratio of 15.1, and a collapse strength of approximately 8400 ksi. In an exemplary embodiment, the expandable tubular members 5200, 5202, 5204, 5206, and 5208 may be radially expanded using the method 4000, illustrated in FIG. 40. In several exemplary embodiments, the tubular members, 5200, 5202, 5204, 5206, and/or 5208, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1 or JFE-B-2 tubulars described above.

In an exemplary experimental embodiment, as illustrated in FIG. 53, an expandable tubular member 5300 included a composition, by weight percentage, of 0.065% C, 1.44% MN, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary experimental embodiment, an expandable tubular member 5302 included a composition, by weight percentage, of 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary experimental embodiment, an expandable tubular member 5304 included a composition, by weight percentage, of 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, 0.05% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary experimental embodiment, an expandable tubular member 5306 included a composition, by weight percentage, of 0.03% C, 1.48% Mn, 0.014% P, 0.002% S, 0.16% Si, 0.02% Cu, 0.01% Ni, 0.02% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

In an exemplary experiment embodiment, as illustrated in FIG. 54, an expandable tubular member 5400 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 16%, a yield strength 5402 change due to expansion of approximately 22%, a yield ratio 5404 change due to radial expansion of approximately 24%, an elongation percentage 5406 change due to radial expansion of approximately 18%, a width reduction percentage 5408 change due to radial expansion of approximately 8%, a wall thickness reduction percentage 5410 change due to radial expansion of approximately 15%, and a anisotropy percentage 5412 change due to radial expansion of approximately 4%. In several exemplary embodiments, the tubular member 5400 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 55, an expandable tubular member 5500 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 15.6%, a yield strength 5502 change due to radial expansion of approximately 70%, a yield ratio 5504 change due to radial expansion of approximately 25%, an elongation percentage 5506 change due to radial expansion of approximately 67%, a width reduction percentage 5508 change due to radial expansion of approximately 28%, a wall thickness reduction percentage 5510 change due to radial expansion of approximately 7%, and a anisotropy percentage 5512 change due to radial expansion of approximately 75%. In several exemplary embodiments, the tubular member 5500 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 56, an expandable tubular member 5600 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 24%, a yield strength 5602 change due to radial expansion of approximately 10%, a yield ratio 5604 change due to radial expansion of approximately 3%, an elongation percentage 5606 change due to radial expansion of approximately 30%, a width reduction percentage 5608 change due to radial expansion of approximately 13%, a wall thickness reduction percentage 5610 change due to radial expansion of approximately 2%, and a anisotropy percentage 5612 change due to radial expansion of approximately 17%. In several exemplary embodiments, the tubular member 5600 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 57, an expandable tubular member 5700 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 24%, a yield strength 5702 change due to radial expansion of approximately 46%, a yield ratio 5704 change due to radial expansion of approximately 20%, an elongation percentage 5706 change due to radial expansion of approximately 91%, a width reduction percentage 5708 change due to radial expansion of approximately 15%, a wall thickness reduction percentage 5710 change due to radial expansion of approximately 2%, and a anisotropy percentage 5712 change due to radial expansion of approximately 18%. In several exemplary embodiments, the tubular member 5700 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 58, an expandable tubular member 5800 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 16%, a yield strength 5802 change due to radial expansion of approximately 38%, a yield ratio 5804 change due to radial expansion of approximately 20%, an elongation percentage 5806 change due to radial expansion of approximately 11%, a width reduction percentage 5808 change due to radial expansion of approximately 9%, a wall thickness reduction percentage 5810 change due to radial expansion of approximately 4%, and a anisotropy percentage 5812 change due to radial expansion of approximately 4%. In several exemplary embodiments, the tubular member 5800 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 59, an expandable tubular member 5900 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 24%, a yield strength 5902 change due to radial expansion of approximately 31%, a yield ratio 5904 change due to radial expansion of approximately 14%, an elongation percentage 5906 change due to radial expansion of approximately 48%, a width reduction percentage 5908 change due to radial expansion of approximately 13%, a wall thickness reduction percentage 5910 change due to radial expansion of approximately 2%, and a anisotropy percentage 5912 change due to radial expansion of approximately 12%. In several exemplary embodiments, the tubular member 5900 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 60, an expandable tubular member 6000 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 24%, a yield strength 6002 change due to radial expansion of approximately 38%, a yield ratio 6004 change due to radial expansion of approximately 21%, an elongation percentage 6006 change due to radial expansion of approximately 55%, a width reduction percentage 6008 change due to radial expansion of approximately 16%, a wall thickness reduction percentage 6010 change due to radial expansion of approximately 9%, and a anisotropy percentage 6012 change due to radial expansion of approximately 13%. In several exemplary embodiments, the tubular member 6000 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 61, an expandable tubular member 6100 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 16%, a yield strength 6102 change due to radial expansion of approximately 33%, a yield ratio 6104 change due to radial expansion of approximately 26%, an elongation percentage 6106 change due to radial expansion of approximately 30%, a width reduction percentage 6108 change due to radial expansion of approximately 15%, a wall thickness reduction percentage 6110 change due to radial expansion of approximately 9%, and a anisotropy percentage 6112 change due to radial expansion of approximately 10%. In several exemplary embodiments, the tubular member 6100 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experiment embodiment, as illustrated in FIG. 62, an expandable tubular member 6200 produced using, for example, the method 3900 illustrated in FIG. 39, included, after a radial expansion of 24%, a yield strength 6202 change due to radial expansion of approximately 41%, a yield ratio 6204 change due to radial expansion of approximately 27%, an elongation percentage 6206 change due to radial expansion of approximately 40%, a width reduction percentage 6208 change due to radial expansion of approximately 21%, a wall thickness reduction percentage 6210 change due to radial expansion of approximately 16%, and a anisotropy percentage 6212 change due to radial expansion of approximately 5%. In several exemplary embodiments, the tubular member 6200 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 63, an expandable tubular member 6300 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6302 of approximately 68 ksi before radial expansion, a yield strength 6304 of approximately 80 ksi after 16% radial expansion, and a yield strength 6306 of approximately 82 ksi after 24% radial expansion. In several exemplary embodiments, the tubular member 6300 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 64, an expandable tubular member 6400 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6402 of approximately 69 ksi before radial expansion, a yield strength 6404 of approximately 83 ksi after 16% radial expansion, and a yield strength 6406 of approximately 88 ksi after 24% radial expansion. In several exemplary embodiments, the tubular member 6400 may be one or more of the X X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 65, an expandable tubular member 6500 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6502 of approximately 80 ksi before radial expansion, a yield strength 6504 of approximately 90 ksi after 16% radial expansion, and a yield strength 6506 of approximately 92 ksi after 24% radial expansion. In several exemplary embodiments, the tubular member 6500 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 66, an expandable tubular member 6600 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6602 of approximately 108 ksi before radial expansion, a yield strength 6604 of approximately 120 ksi after 15.2% radial expansion, and a yield strength 6606 of approximately 121 ksi after 25.2% radial expansion. In several exemplary embodiments, the tubular member 6600 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 67, an expandable tubular member 6700 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6702 of approximately 100 ksi before radial expansion and a yield strength 6704 of approximately 127 ksi after 31.3% radial expansion. In several exemplary embodiments, the tubular member 6700 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 68 a and 68 b, an expandable tubular member 6800 produced using, for example, the method 3900 illustrated in FIG. 39, included a yield strength 6802 of approximately 118 ksi before radial expansion and a yield strength 6804 of approximately 140 ksi after 15.6% radial expansion. In an exemplary experimental embodiment, an expandable tubular member 6806 is produced using, for example, the method 3900 illustrated in FIG. 39, that includes a yield strength of approximately 51 ksi, a yield strength to tensile strength ratio of approximately 0.44, a longitudinal elongation change due to radial expansion of approximately 12%, a width reduction due to radial expansion of approximately 18%, a wall thickness reduction due to radial expansion of approximately 15%, and an anisotropy of approximately 1.24. In several exemplary embodiments, the tubular members, 6800 and 6806, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 69, an expandable tubular member 6900 begins with a tensile strength 6902 of approximately 85 ksi and a yield strength 6904 of approximately 55 ksi. After quenching in water at approximately 775° C., the expandable tubular member 6900 includes a tensile strength 6908 of 94 ksi and a yield strength 6910 of 56 ksi. In an exemplary embodiment, the expandable tubular member 6900 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 6900 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 70, an expandable tubular member 7000 begins with a tensile strength 7002 of approximately 69 ksi and a yield strength 7004 of approximately 45 ksi. After quenching in water at approximately 790° C., the expandable tubular member 7000 includes a tensile strength 7008 of 94 ksi and a yield strength 7010 of 59 ksi. In an exemplary embodiment, the expandable tubular member 7000 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7000 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 71, an expandable tubular member 7100 begins with a tensile strength 7102 of approximately 80 ksi and a yield strength 7104 of approximately 59 ksi. After quenching in water at approximately 735° C., the expandable tubular member 7100 includes a tensile strength 7108 of 94 ksi and a yield strength 7110 of 59 ksi. In an exemplary embodiment, the expandable tubular member 7100 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7100 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 72, an expandable tubular member 7200 begins with a tensile strength 7202 of approximately 75 ksi and a yield strength 7204 of approximately 55 ksi. After quenching in oil at approximately 775° C., the expandable tubular member 7200 includes a tensile strength 7208 of 84 ksi and a yield strength 7210 of 49 ksi. In an exemplary embodiment, the expandable tubular member 7200 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7200 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 73, an expandable tubular member 7300 begins with a tensile strength 7302 of approximately 69 ksi and a yield strength 7304 of approximately 45 ksi. After quenching in oil at approximately 820° C., the expandable tubular member 7300 includes a tensile strength 7308 of 92 ksi and a yield strength 7310 of 61 ksi. In an exemplary embodiment, the expandable tubular member 7300 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7300 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 74, an expandable tubular member 7400 begins with a tensile strength 7402 of approximately 80 ksi and a yield strength 7404 of approximately 60 ksi. After quenching in oil at approximately 750° C., the expandable tubular member 7400 includes a tensile strength 7408 of 109 ksi and a yield strength 7410 of 58 ksi. In an exemplary embodiment, the expandable tubular member 7400 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7400 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 75, expandable tubular members, 7500, 7502 and 7504, are produced by quenching and tempering. Expandable tubular member 7500 includes a yield strength 7506 of approximately 80, a yield strength to tensile strength ratio 7508 of approximately 0.86, an elongation change due to radial expansion 7510 of approximately 14.8%, a width reduction due to radial expansion 7512 of approximately 38%, a wall thickness reduction due to radial expansion 7514 of approximately 43%, and an anisotropy 7516 of approximately 0.87. Expandable tubular member 7502 includes a yield strength 7506 of approximately 81, a yield strength to tensile strength ratio 7508 of approximately 0.83, an elongation change due to radial expansion 7510 of approximately 14.9%, a width reduction 7512 of approximately 38%, a wall thickness reduction due to radial expansion 7514 of approximately 43.3%, and an anisotropy 7516 of approximately 0.83. Expandable tubular member 7504 includes a yield strength 7506 of approximately 79, a yield strength to tensile strength ratio 7508 of approximately 0.82, an elongation change due to radial expansion 7510 of approximately 15.9%, a width reduction due to radial expansion 7512 of approximately 44%, a wall thickness reduction due to radial expansion 7514 of approximately 43.3%, and an anisotropy 7516 of approximately 1.03. In an exemplary embodiment, the expandable tubular member 7500 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular members, 7500, 7502, and/or 7504, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 76, expandable tubular members, 7600 and 7602, are produced by quenching and tempering. Expandable tubular member 7600 includes a yield strength 7504 of approximately 80 ksi, a yield strength to tensile strength ratio 7506 of approximately 0.86, an elongation change due to radial expansion 7508 of approximately 14.8%, a width reduction due to radial expansion 7510 of approximately 38%, a wall thickness reduction due to radial expansion 7512 of approximately 43%, and an anisotropy 7514 of approximately 0.87. Expandable tubular member 7502 includes a yield strength 7504 of approximately 80 ksi, a yield strength to tensile strength ratio 7506 of approximately 0.83, an elongation change due to radial expansion 7508 of approximately 15.3%, a width reduction due to radial expansion 7510 of approximately 40.4%, a wall thickness reduction due to radial expansion 7512 of approximately 43.3%, and an anisotropy 7514 of approximately 0.92. In an exemplary embodiment, the expandable tubular member 7600 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular members, 7600 and 7602, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIGS. 77 a and 77 b, an expandable tubular member 7700 may be produced, for example, using the method 4000 of FIG. 40, including an elongation change due to radial expansion of 21%, a width reduction due to radial expansion of 35%, a wall thickness reduction due to radial expansion of 38%, and an anisotropy of 0.89. Expandable tubular member 7700 includes a stress-strain curve 7702 including a tensile strength of approximately 100 ksi. In an exemplary embodiment, the expandable tubular member 7700 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7700 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIGS. 78 a and 78 b, an expandable tubular member 7800 was produced by quenching and tempering that included a yield strength of approximately 85 ksi, a yield strength to tensile strength ratio of approximately 0.85, a longitudinal elongation change due to radial expansion of approximately 21%, a width reduction due to radial expansion of approximately 39%, a wall thickness reduction due to radial expansion of 43%, and an anisotropy of 0.88. Expandable tubular member 7800 includes a stress-strain curve 7802 including a tensile strength of approximately 100 ksi. In an exemplary embodiment, the expandable tubular member 7800 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7800 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIGS. 79 a and 79 b, an expandable tubular member 7900 was produced by quenching and tempering that included a yield strength of approximately 89 ksi, a yield strength to tensile strength ratio of approximately 0.86, a longitudinal elongation change due to radial expansion of approximately 22%, a width reduction due to radial expansion of approximately 39%, a wall thickness reduction due to radial expansion of 41%, and an anisotropy of 0.93. Expandable tubular member 7900 includes a stress-strain curve 7902 including a tensile strength of approximately 100 ksi. In an exemplary embodiment, the expandable tubular member 7900 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 7900 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIGS. 80 a and 80 b, an expandable tubular member 8000 was produced by quenching and tempering that included a yield strength of approximately 84 ksi, a yield strength to tensile strength ratio of approximately 0.84, a longitudinal elongation change due to radial expansion of approximately 21%, a width reduction due to radial expansion of approximately 40%, a wall thickness reduction due to radial expansion of 42%, and an anisotropy of 0.94. Expandable tubular member 8002 includes a stress-strain curve 7902 including a tensile strength of approximately 108 ksi. In an exemplary embodiment, the expandable tubular member 8000 may be produced using, for example, the method 3900 illustrated in FIG. 39. In several exemplary embodiments, the tubular member 8000 may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary experimental embodiment, as illustrated in FIG. 81, an expandable tubular member 8100 may be produced, for example, using the method 3900 of FIG. 39, including a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.72, an elongation change due to radial expansion of approximately 35%, a width reduction due to radial expansion of approximately 35%, a wall thickness reduction due to radial expansion of approximately 33%, and an anisotropy of approximately 0.92. In an exemplary embodiment, expandable tubular member 8100 is produced by hot stretching, reducing at 1950° C., and rotary straightening. An expandable tubular member 8102 was produced that included a yield strength of approximately 90 ksi, a yield strength to tensile strength ratio of approximately 0.88, an elongation change due to radial expansion of approximately 25%, a width reduction due to radial expansion of approximately 22%, a wall thickness reduction due to radial expansion of approximately 20%, and an anisotropy of approximately 1.1. In an exemplary embodiment, expandable tubular member 8102 is produced by normalizing at 1850° C., cold drawing, annealing at 1050° C., and rotary straightening. An expandable tubular member 8104 was produced that included a yield strength of approximately 88 ksi, a yield strength to tensile strength ratio of approximately 0.87, an elongation change due to radial expansion of approximately 16%, a width reduction due to radial expansion of approximately 24%, a wall thickness reduction due to radial expansion of approximately 30%, and an anisotropy of approximately 0.76. In an exemplary embodiment, expandable tubular member 8104 is produced by hot stretching, reducing at 1950° C., cold drawing, annealing, and rotary straightening. An expandable tubular member 8106 was produced that included a yield strength of approximately 48 ksi, a yield strength to tensile strength ratio of approximately 0.73, an elongation change due to radial expansion of approximately 38%, a width reduction due to radial expansion of approximately 43%, a wall thickness reduction due to radial expansion of approximately 49%, and an anisotropy of approximately 0.83. In an exemplary embodiment, expandable tubular member 8106 is produced by hot stretching, reducing at 1850° C., and rotary straightening. An expandable tubular member 8108 was produced that included a yield strength of approximately 46 ksi, a yield strength to tensile strength ratio of approximately 0.69, an elongation change due to radial expansion of approximately 40%, a width reduction due to radial expansion of approximately 50%, a wall thickness reduction due to radial expansion of approximately 53%, and an anisotropy of approximately 0.93. In an exemplary embodiment, expandable tubular member 8108 is produced by hot reducing at 1850° C., cold sizing, and rotary straightening. An expandable tubular member 8110 was produced that included a yield strength of approximately 53 ksi, a yield strength to tensile strength ratio of approximately 0.85, an elongation change due to radial expansion of approximately 49%, a width reduction due to radial expansion of approximately 49%, a wall thickness reduction due to radial expansion of approximately 2046 and an anisotropy of approximately 1.1. In an exemplary embodiment, expandable tubular member 8110 is produced by hot stretching, reducing at 1850° C., and rotary straightening. In several exemplary embodiments, the tubular members, 8100, 8102, 8104, 8106, 8108, and 8110, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In an exemplary embodiment, as illustrated in FIG. 82, an expandable tubular member 8200 may be produced, for example, using the method 3900 of FIG. 39, including a 42% flare expansion, absorbed energy in the longitudinal direction of 125 ft-lbs, absorbed energy in the transverse direction of 59 ft-lbs, and absorbed energy in the weld of 176 ft-lbs. An expandable tubular member 8202 was produced that included a 52% flare expansion, absorbed energy in the longitudinal direction of 145 ft-lbs, absorbed energy in the transverse direction of 59 ft-lbs, and absorbed energy in the weld of 174 ft-lbs. In several exemplary embodiments, the tubular members, 8200 and 8202, may be one or more of the X-52-1, X-52-2, JFE-A-1, JFE-A-2, JFE-B-1, JFE-B-2, 5302, 5304, 5306 or 5308 tubular members described above.

In several exemplary embodiments, the teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841 626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, the disclosure of which is incorporated herein by reference.

A method of forming a tubular liner within a preexisting structure has been described that includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the method further includes positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings include the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings include the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members include the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings include slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly is a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, the hard phase structure comprises martensite. In an exemplary embodiment, the soft phase structure comprises ferrite. In an exemplary embodiment, the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.

An expandable tubular member has been described that includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and a yield point of the tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the tubular member after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described that includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 57.8 ksi prior to a radial expansion and plastic deformation; and the yield point of the tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, a yield point of the of the tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described that includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described that includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

A method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

A system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

A method of manufacturing a tubular member has been described that includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation. In an exemplary embodiment, the characteristics are selected from a group consisting of yield point and ductility. In an exemplary embodiment, processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics includes: radially expanding and plastically deforming the tubular member within the preexisting structure.

An apparatus has been described that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the expansion device includes a rotary expansion device, an axially displaceable expansion device, a reciprocating expansion device, a hydroforming expansion device, and/or an impulsive force expansion device. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, wherein the hard phase structure comprises martensite. In an exemplary embodiment, wherein the soft phase structure comprises ferrite. In an exemplary embodiment, wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: pearlite or pearlite striation. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.

An expandable tubular member has been described, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

A method of determining the expandability of a selected tubular member has been described that includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member. In an exemplary embodiment, an anisotropy value greater than 0.12 indicates that the tubular member is suitable for radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.

A method of radially expanding and plastically deforming tubular members has been described that includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, radially expanding and plastically deforming the selected tubular member includes: inserting the selected tubular member into a preexisting structure; and then radially expanding and plastically deforming the selected tubular member. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation.

A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges.

A method of joining radially expandable multiple tubular members has also been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members. In an exemplary embodiment, the method further includes providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes providing a recess in each tubular member. In an exemplary embodiment, the method further includes engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.

A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein at least a portion of the sleeve is comprised of a frangible material.

A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein the wall thickness of the sleeve is variable.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a frangible material; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a variable wall thickness; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.

In several exemplary embodiments of the apparatus described above, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.

In several exemplary embodiments of the method described above, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression before, during, and/or after the radial expansion and plastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, a tubular sleeve coupled to and receiving end portions of the first and second tubular members, and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member, wherein the sealing element is positioned within an annulus defined between the first and second tubular members. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, providing a sleeve, mounting the sleeve for overlapping and coupling the first and second tubular members, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, and sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.

An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, providing a plurality of sleeves, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings.

An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, providing a plurality of sleeves, coupling the first and second tubular members, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.

An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a threaded connection for coupling a portion of the first and second tubular members, and a tubular sleeves coupled to and receiving end portions of the first and second tubular members, wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members, and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom, and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.

A radially expandable multiple tubular member apparatus has been described that includes a first tubular member, a second tubular member engaged with the first tubular member forming a joint, a sleeve overlapping and coupling the first and second tubular members at the joint, and one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.

A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, engaging a second tubular member with the first tubular member to form a joint, providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange, and concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint.

A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members, and means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.

A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.

A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.

A radially expandable tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.36. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the apparatus further includes a threaded connection for coupling a portion of the first and second tubular members; wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression and tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for avoiding stress risers in the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the wall thickness of the sleeve is variable. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.

A radially expandable tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.

A method of joining radially expandable tubular members has been provided that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members; and concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the sleeve comprises a variable wall thickness. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; providing a plurality of sleeves; and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings. In an exemplary embodiment, the method further includes: threadably coupling the first and second tubular members; and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.

A method of joining radially expandable tubular members has been described that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the method further includes: providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes: providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes: providing a recess in each tubular member. In an exemplary embodiment, the method further includes: engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes: providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.

An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the assembly further includes: positioning another assembly within the preexisting structure in overlapping relation to the assembly; and radially expanding and plastically deforming the other assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the assembly, a predetermined portion of the other assembly has a lower yield point than another portion of the other assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of spaced apart predetermined portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of other portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of spaced apart other portions of the assembly. In an exemplary embodiment, the assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the assembly; and wherein the tubular members comprise the other portion of the assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly is greater than the expandability coefficient of the other portion of the assembly. In an exemplary embodiment, the assembly comprises a wellbore casing. In an exemplary embodiment, the assembly comprises a pipeline. In an exemplary embodiment, the assembly comprises a structural support. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.

A method of joining radially expandable tubular members is provided that includes providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support. In an exemplary embodiment, the sleeve comprises: a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; wherein at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; and wherein at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections. In an exemplary embodiment, the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21. In an exemplary embodiment, the tubular member comprises a wellbore casing.

An expandable tubular member has been described, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36. In an exemplary embodiment, the tubular member comprises a wellbore casing.

A method of selecting tubular members for radial expansion and plastic deformation has been described that includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.

A method of selecting tubular members for radial expansion and plastic deformation has been described that includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.

An expandable tubular member has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.

A method of manufacturing an expandable tubular member has been described that includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: pearlite or pearlite striation. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the heat treating comprises heating the provided tubular member for about 10 minutes at 790° C. In an exemplary embodiment, the quenching comprises quenching the heat treated tubular member in water. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi. In an exemplary embodiment, the method further includes: positioning the quenched tubular member within a preexisting structure; and radially expanding and plastically deforming the tubular member within the preexisting structure.

A method for manufacturing an expandable tubular member has been described that includes providing a tubular member, heat treating the tubular member, quenching the tubular member, and cold working the tubular member, whereby upon cold working, the yield strength of the material is increased. In an exemplary embodiment, the tubular member is a connection for an expandable tubular member. In an exemplary embodiment, the yield strength increases from approximately 35 ksi to 80 ksi.

A method for expanding an expandable tubular member has been described that includes providing a tubular member, lubricating the tubular member, and expanding the tubular member. In an exemplary embodiment, the tubular member is a connection for an expandable tubular member.

A method for formability evaluation has been described that includes providing a tubular member, measuring a plurality of stress and strain property parameters for the tubular member, measuring a Charpy V-notch impact value parameter for the tubular member, measuring a stress rupture parameter for the tubular member, measuring a strain hardening exponent parameter for the tubular member, measuring a plastic strain ratio parameter for the tubular member, comparing the parameters measured for first tubular member to a plurality of parameters measured for a second tubular member, and selecting the first or second tubular member to manufacture an expandable tubular member. In an exemplary embodiment, the stress rupture parameter includes a parameter for burst. In an exemplary embodiment, the stress rupture parameter includes a parameter for collapse. In an exemplary embodiment, a tubular member with a plastic strain ratio parameter of greater than 1.0 will be more resistant to thinning and better suited to tubular expansion.

An expandable tubular member has been described that includes a tensile strength in the range of 60 ksi to 120 ksi, a yield strength in the range of 40 ksi to 100 ksi, a yield strength to tensile strength ratio in the range of 50% to 85%, a minimum elongation of 35%, a minimum width reduction of 40%, a minimum thickness reduction of 30%, and a minimum anisotropy of 1.5. In an exemplary embodiment, the expandable tubular member further includes a minimum flare expansion of 45%. In an exemplary embodiment, the expandable tubular member further includes a minimum absorbed energy at negative 4 degrees Fahrenheit of 80 ft-lbs in the longitudinal direction, 60 ft-lbs in the transverse direction, and 60 ft lbs in the transverse weld area.

A method for transforming the yield strength of an expandable tubular member has been described that includes providing a manufactured tubular member, cold rolling the tubular member, inter-critical annealing the tubular member, expanding the tubular member, and heating the tubular member. In an exemplary embodiment, the tubular member comprises a dual steel composition comprising, by weight percentage, 0.12% C, 0.4% Si, 1.5% Mn, and 0.02% Nb.

An expandable tubular member has been described that includes a tensile strength in the range of 80 ksi to 100 ksi, a yield strength in the range of 60 ksi to 90 ksi, a maximum yield strength to tensile strength ratio of 85%, a minimum elongation of 22%, a minimum width reduction of 30%, a minimum thickness reduction of 35%, and a minimum anisotropy of 0.8. In an exemplary embodiment, the expandable tubular member further includes a minimum flare expansion of 45%. In an exemplary embodiment, the expandable tubular member further includes a minimum absorbed energy at negative 4 degrees Fahrenheit of 80 ft-lbs in a longitudinal direction, 60 ft-lbs in a transverse direction, and 60 ft lbs in a transverse weld area.

An expandable tubular member has been described that includes a tensile strength in the range of 60 ksi to 120 ksi, a yield strength in the range of 40 ksi to 100 ksi, a yield strength to tensile strength ratio in the range of 50% to 85%, a minimum elongation of 35%, a minimum width reduction of 40%, a minimum thickness reduction of 30%, and a minimum anisotropy of 1.5. In an exemplary embodiment, the expandable tubular member further includes a minimum flare expansion of 75%. In an exemplary embodiment, the expandable tubular member further includes a minimum absorbed energy at negative 4 degrees Fahrenheit of 80 ft-lbs in a longitudinal direction, 60 ft-lbs in a transverse direction, and 60 ft lbs in a transverse weld area.

A method for transforming the yield strength of an expandable tubular member has been described that includes providing a manufactured tubular member, inter-critical annealing the tubular member, expanding the tubular member, and heating the tubular member.

An expandable tubular member has been described that includes a yield strength of approximately 76 ksi, a tensile strength of approximately 82 ksi, and an elongation of approximately 32%.

An expandable tubular member has been described that includes a surface, a self lubricating hard coating on the surface, and a self lubricating soft coating on the surface. In an exemplary embodiment, the self-lubricating soft coating comprises film grease. In an exemplary embodiment, the self lubricating soft coating comprises a lubricated mud. In an exemplary embodiment, the self lubricating soft coating comprises a film grease and a lubricated mud. In an exemplary embodiment, the member comprises a friction coefficient of not more than 0.05. In an exemplary embodiment, the member comprises a friction coefficient of approximately 0.05. In an exemplary embodiment, the member comprises a friction coefficient of approximately 0.075. In an exemplary embodiment, the member comprises a friction coefficient of approximately 0.1. In an exemplary embodiment, the member comprises a friction coefficient of approximately 0.125.

An expandable tubular member has been described that includes a yield strength in the range of 40 ksi to 80 ksi, a maximum yield strength to tensile strength ratio of 0.5, a minimum elongation of 30%, a minimum width reduction of 45%, a minimum wall thickness reduction of 30%, and a minimum anisotropy of 1.5.

An expandable tubular member has been described that includes a friction coefficient of 0.02, whereby the member may be expanded by a force below 100000 lbs. In an exemplary embodiment, the member has approximately a 6 inch diameter.

An expandable tubular member has been described that includes a lubricant resulting in a friction coefficient of 0.125, a wall thickness of approximately 0.305 inches, and an expansion force of approximately 146000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 25 and a collapse strength of approximately 2400 ksi.

An expandable tubular member has been described that includes a lubricant resulting in a friction coefficient of 0.075, a wall thickness of approximately 0.350 inches, and an expansion force of approximately 143000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 22 and a collapse strength of approximately 3250 ksi.

An expandable tubular member has been described that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.450 inches, and an expansion force of approximately 150000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 17 and a collapse strength of approximately 5800 ksi.

An expandable tubular member has been described that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.5 inches, and an expansion force of approximately 126000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 15 and a collapse strength of approximately 5350 ksi. In an exemplary embodiment, the member includes a 55 ksi steel.

An expandable tubular member has been described that includes a lubricant resulting in a friction coefficient of 0.02, a wall thickness of approximately 0.5 inches, and an expansion force of approximately 127000 lbs, wherein the expansion force allows a diameter to thickness ratio of approximately 15 and a collapse strength of approximately 8400 ksi. In an exemplary embodiment, the member includes a steel with a 55 ksi yield before expansion and a 100 ksi yield after expansion.

An expandable tubular member has been described that includes a composition, by weight percentage, of 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

An expandable tubular member has been described that includes a composition, by weight percentage, of 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.

An expandable tubular member has been described that includes a composition, by weight percentage, of 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.3% Si, 0.16% Cu, 0.05% Ni, 0.05% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

An expandable tubular member has been described that includes a composition, by weight percentage, of 0.03% C, 1.48% Mn, 0.014% P, 0.002% S, 0.16% Si, 0.02% Cu, 0.01% Ni, 0.02% Cr, 0.06% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.

An expandable tubular member has been described that includes, after a 16% expansion, approximately a 21% change in yield strength, approximately a 24% change in yield ratio, approximately a 18% change in elongation percentage, approximately a 8% change in width reduction percentage, approximately a 15% change in wall thickness reduction percentage, and approximately a 4% change in anisotropy.

An expandable tubular member has been described that includes, after a 15.6% expansion, approximately a 70% change in yield strength, approximately a 25% change in yield ratio, approximately a 67% change in elongation percentage, approximately a 28% change in width reduction percentage, approximately a 7% change in wall thickness reduction percentage, and approximately a 75% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 5% change in yield strength, approximately a 11% change in yield ratio, approximately a 20% change in elongation percentage, approximately a 43% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 52% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 10% change in yield strength, approximately a 3% change in yield ratio, approximately a 30% change in elongation percentage, approximately a 13% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 17% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 46% change in yield strength, approximately a 20% change in yield ratio, approximately a 91% change in elongation percentage, approximately a 15% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 18% change in anisotropy.

An expandable tubular member has been described that includes, after a 16% expansion, approximately a 38% change in yield strength, approximately a 20% change in yield ratio, approximately a 11% change in elongation percentage, approximately a 9% change in width reduction percentage, approximately a 4% change in wall thickness reduction percentage, and approximately a 4% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 31% change in yield strength, approximately a 14% change in yield ratio, approximately a 48% change in elongation percentage, approximately a 13% change in width reduction percentage, approximately a 2% change in wall thickness reduction percentage, and approximately a 12% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 38% change in yield strength, approximately a 21% change in yield ratio, approximately a 55% change in elongation percentage, approximately a 16% change in width reduction percentage, approximately a 9% change in wall thickness reduction percentage, and approximately a 13% change in anisotropy.

An expandable tubular member has been described that includes, after a 16% expansion, approximately a 33% change in yield strength, approximately a 26% change in yield ratio, approximately a 30% change in elongation percentage, approximately a 15% change in width reduction percentage, approximately a 9% change in wall thickness reduction percentage, and approximately a 10% change in anisotropy.

An expandable tubular member has been described that includes, after a 24% expansion, approximately a 41% change in yield strength, approximately a 27% change in yield ratio, approximately a 40% change in elongation percentage, approximately a 21% change in width reduction percentage, approximately a 16% change in wall thickness reduction percentage, and approximately a 5% change in anisotropy.

An expandable tubular member has been described that includes a tensile strength of approximately 80 ksi after 16% expansion, and a tensile strength of approximately 82 ksi after 24% expansion.

An expandable tubular member has been described that includes a tensile strength of approximately 82 ksi after 16% expansion, and a tensile strength of approximately 88 ksi after 24% expansion.

An expandable tubular member has been described that includes a tensile strength of approximately 80 ksi before expansion, a tensile strength of approximately 90 ksi after 16% expansion, and a tensile strength of approximately 92 ksi after 24% expansion.

An expandable tubular member has been described that includes a tensile strength of approximately 115 ksi before expansion, a tensile strength of approximately 120 ksi after 15.2% expansion, and a tensile strength of approximately 121 ksi after 25.2% expansion.

An expandable tubular member has been described that includes a tensile strength of approximately 100 ksi before expansion, and a tensile strength of approximately 126 ksi after 31.3% expansion.

An expandable tubular member has been described that includes a tensile strength of approximately 114 ksi before expansion, and a tensile strength of approximately 140 ksi after 15.6% expansion.

An expandable tubular member has been described that includes, upon quenching in water at approximately 775° C., a tensile strength of 94 ksi and a yield strength of 56 ksi.

An expandable tubular member has been described that includes, upon quenching in water at approximately 790° C., a tensile strength of 94 ksi and a yield strength of 59 ksi.

An expandable tubular member has been described that includes, upon quenching in water at approximately 735° C., a tensile strength of 94 ksi and a yield strength of 59 ksi.

An expandable tubular member has been described that includes, upon quenching in oil at approximately 775° C., a tensile strength of 84 ksi and a yield strength of 49 ksi.

An expandable tubular member has been described that includes, upon quenching in oil at approximately 820° C., a tensile strength of 82 ksi and a yield strength of 61 ksi.

An expandable tubular member has been described that includes, upon quenching in oil at approximately 750° C., a tensile strength of 109 ksi and a yield strength of 58 ksi.

An expandable tubular member has been described that includes, by weight percentage, 0.1% C, 1.5% Mn, and 0.3% Si. In an exemplary embodiment, the member further includes martensite in the range of 15% to 30%.

An expandable tubular member has been described that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.86, a longitudinal elongation of approximately 14.8%, a width reduction of approximately 38%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.87.

An expandable tubular member has been described that includes a yield strength of approximately 81 ksi, a yield strength to tensile strength ratio of approximately 0.83, a longitudinal elongation of approximately 14.9%, a width reduction of approximately 38%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.83.

An expandable tubular member has been described that includes a yield strength of approximately 79 ksi, a yield strength to tensile strength ratio of approximately 0.82, a longitudinal elongation of approximately 15.9%, a width reduction of approximately 44%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 1.03.

An expandable tubular member has been described that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.83, a longitudinal elongation of approximately 15.3%, a width reduction of approximately 40%, a wall thickness reduction of approximately 43%, and an anisotropy of approximately 0.92.

An expandable tubular member has been described that includes an elongation of approximately 21%, a width reduction of approximately 35%, a wall thickness reduction of approximately 38%, and an anisotropy of approximately 0.89.

An expandable tubular member has been described that includes a yield strength of approximately 77 ksi, a yield strength to tensile strength ratio of approximately 0.82, a longitudinal elongation of approximately 16%, a width reduction of approximately 32%, a wall thickness reduction of approximately 45%, and an anisotropy of approximately 0.65.

An expandable tubular member has been described that includes a yield strength of approximately 78 ksi, a yield strength to tensile strength ratio of approximately 0.8, a longitudinal elongation of approximately 16%, a width reduction of approximately 31%, a wall thickness reduction of approximately 45%, and an anisotropy of approximately 0.63.

An expandable tubular member has been described that includes, upon quenching and tempering, a yield strength of approximately 84 ksi, a yield strength to tensile strength ratio of approximately 0.84, a longitudinal elongation of approximately 20.5%, a width reduction of approximately 40%, a wall thickness reduction of approximately 42%, and an anisotropy of approximately 0.94.

An expandable tubular member has been described that includes a yield strength of approximately 80 ksi, a yield strength to tensile strength ratio of approximately 0.72, an elongation of approximately 35%, a width reduction of approximately 35%, a wall thickness reduction of approximately 33%, and an anisotropy of approximately 0.92. In an exemplary embodiment, the member is processed comprising the steps of hot stretching, reducing at approximately 1950° C., and rotary straightening.

An expandable tubular member has been described that includes a yield strength of approximately 90 ksi, a yield strength to tensile strength ratio of approximately 0.88, an elongation of approximately 25%, a width reduction of approximately 22%, a wall thickness reduction of approximately 20%, and an anisotropy of approximately 1.1. In an exemplary embodiment, the member is processed comprising the steps of normalization at approximately 1850° C., cold drawing, annealing at approximately 1050° C., and rotary straightening.

An expandable tubular member has been described that includes a yield strength of approximately 88 ksi, a yield strength to tensile strength ratio of approximately 0.87, an elongation of approximately 16%, a width reduction of approximately 24%, a wall thickness reduction of approximately 30%, and an anisotropy of approximately 0.76. In an exemplary embodiment, the member is processed comprising the steps of hot stretching, reducing at approximately 1950° C., cold drawing, annealing, and rotary straightening.

An expandable tubular member has been described that includes a yield strength of approximately 48 ksi, a yield strength to tensile strength ratio of approximately 0.73, an elongation of approximately 38%, a width reduction of approximately 43%, a wall thickness reduction of approximately 49%, and an anisotropy of approximately 0.83. In an exemplary embodiment, the member is processed comprising the steps of hot stretching, reducing at approximately 1850° C., and rotary straightening.

An expandable tubular member has been described that includes a yield strength of approximately 46 ksi, a yield strength to tensile strength ratio of approximately 0.69, an elongation of approximately 40%, a width reduction of approximately 50%, a wall thickness reduction of approximately 53%, and an anisotropy of approximately 0.93. In an exemplary embodiment, the member is processed comprising the steps of hot reducing at approximately 1850° C., cold sizing, and rotary straightening.

An expandable tubular member has been described that includes a yield strength of approximately 53 ksi, a yield strength to tensile strength ratio of approximately 0.85, an elongation of approximately 49%, a width reduction of approximately 49%, a wall thickness reduction of approximately 46%, and an anisotropy of approximately 1.1. In an exemplary embodiment, the member is processed comprising the steps of hot stretching, reducing at approximately 1850° C., and rotary straightening.

An expandable tubular member has been described that includes, upon quenching and tempering, after a flare expansion of 42%, an absorbed energy in the longitudinal direction of 125 ft-lbs, an absorbed energy in the transverse direction of 59 ft-lbs, and an absorbed energy in the weld of 176 ft-lbs.

An expandable tubular member has been described that includes, upon quenching and tempering, after a flare expansion of 52%, an absorbed energy in the longitudinal direction of 145 ft-lbs, an absorbed energy in the transverse direction of 59 ft-lbs and an absorbed energy in the weld of 174 ft-lbs.

It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrated embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.

Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. 

1. A method of forming a tubular liner within a preexisting structure, comprising: positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
 2. An expandable tubular member comprising a steel alloy comprising, by weight percentage: 0.065 to 0.08% C, 0.82 to 1.44% Mn, 0.006 to 0.02% P, 0.001 to 0.004% S, 0.24 to 0.45% Si, up to 0.05% Cu, 0.01 to 9.1% Ni, and 0.02 to 18.7% Cr.
 3. An expandable tubular member, wherein a yield point of the expandable tubular member is at most about 46.9 to 57.8 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 to 74.4 ksi after the radial expansion and plastic deformation.
 4. An expandable tubular member, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8 to 40% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
 5. An expandable tubular member, wherein an anisotropy of the expandable tubular member, prior to a radial expansion and plastic deformation of the expandable tubular member, is at least about 1.04 to 1.92.
 6. An expandable tubular member, wherein an expandability coefficient of the expandable tubular member, prior to a radial expansion and plastic deformation of the expandable tubular member, is greater than 0.12.
 7. An expandable tubular member, wherein an expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
 8. An expandable tubular member wherein the expandable tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation of the expandable tubular member than after the radial expansion and plastic deformation of the expandable tubular member. 9-126. (canceled)
 127. A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member coupled to a second tubular member, comprising: radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member. 128-134. (canceled)
 135. A method of manufacturing a tubular member, comprising: processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics. 136-141. (canceled)
 142. An apparatus, comprising: an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly. 143-193. (canceled)
 194. A method of determining the expandability of a selected tubular member, comprising: determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member. 195-198. (canceled)
 199. A method of radially expanding and plastically deforming tubular members, comprising: selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the expandability value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member. 200-204. (canceled)
 205. A radially expandable tubular member apparatus comprising: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus. 206-309. (canceled)
 310. A method of joining radially expandable tubular members comprising: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. 311-515. (canceled)
 516. An expandable tubular member wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21 to 0.36. 517-666. (canceled)
 667. A method of selecting tubular members for radial expansion and plastic deformation, comprising: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21 to 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation. 668-672. (canceled)
 673. An expandable tubular member, comprising: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. 674-728. (canceled)
 729. A method of manufacturing an expandable tubular member, comprising: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure. 730-757. (canceled)
 758. A method for manufacturing an expandable tubular member comprising: providing a tubular member; heat treating the tubular member; quenching the tubular member; and cold working the tubular member, whereby upon cold working, the yield strength of the tubular member is increased. 759-760. (canceled)
 761. A method for expanding an expandable tubular member comprising: providing a tubular member; lubricating the tubular member; and expanding the tubular member.
 763. (canceled)
 763. A method for formability evaluation comprising: selecting a first tubular member; measuring a plurality of stress and strain property parameters for the first tubular member; measuring a Charpy V-notch impact value parameter for the first tubular member; measuring a stress rupture parameter for the first tubular member; measuring a strain hardening exponent parameter for the first tubular member; measuring a plastic strain ratio parameter for the first tubular member; comparing the parameters measured for first tubular member to a plurality of desired parameters; and selecting the first tubular member to manufacture an expandable tubular member if the measured parameters meet or exceed the desired parameters. 764-766. (canceled)
 767. An expandable tubular member comprising: a tensile strength in the range of 60 ksi to 120 ksi; a yield strength in the range of 40 ksi to 100 ksi; a yield strength to tensile strength ratio in the range of 50% to 85%; a minimum elongation change due to radial expansion of 35%; a minimum width reduction due to radial expansion of 40%; a minimum thickness reduction due to radial expansion of 30%; and a minimum anisotropy of 1.5. 768-769. (canceled)
 770. A method for transforming the yield strength of an expandable tubular member comprising: providing a manufactured tubular member; inter-critical annealing the tubular member; radially expanding and plastically deforming the tubular member; and heating the tubular member. 771-774. (canceled)
 775. An expandable tubular member comprising: a tensile strength in the range of 60 ksi to 120 ksi; a yield strength in the range of 40 ksi to 100 ksi; a yield strength to tensile strength ratio in the range of 50% to 85%; a minimum elongation change due to radial expansion of 22% to 35%; a minimum width reduction due to radial expansion of 30% to 40%; a minimum thickness reduction due to radial expansion of 30% to 35%; and a minimum anisotropy of 0.8 to 1.5. 776-778. (canceled)
 779. An expandable tubular member comprising: a yield strength of approximately 77 ksi; a tensile strength of approximately 83 ksi; and an elongation of approximately 32%.
 780. An expansion device comprising: a surface; a self lubricating hard coating on the surface; and a self lubricating soft coating on the surface. 781-788. (canceled)
 789. An expandable tubular member comprising: a yield strength in the range of 40 ksi to 80 ksi; a maximum yield strength to tensile strength ratio of 0.5; a minimum elongation change due to radial expansion of 30%; a minimum width reduction due to radial expansion of 45%; a minimum wall thickness reduction due to radial expansion of 30%; and a minimum anisotropy of 1.5.
 790. An expandable tubular member comprising: a friction coefficient between the expandable tubular member and an expansion device of 0,02, whereby the member may be expanded by a force below 100000 lbs.
 791. (canceled)
 792. An expandable tubular member comprising: a lubricant resulting in a friction coefficient of 0.02 to 0.125 between the expandable tubular member and an expansion device; a wall thickness of approximately 0.305 to 0.5 inches; and a required expansion force of approximately 126000 lbs to 146000 lbs; wherein the required expansion force allows a diameter to thickness ratio of approximately 15 to 25 and a collapse strength of approximately 2400 ksi. 793-803. (canceled)
 804. An expandable tubular member, comprising: wherein after a 15.6% to 24% radial expansion and plastic deformation, approximately a 5% to 70% change in yield strength, approximately a 3% to 27% change in yield ratio, approximately a 11% to 91% change in elongation percentage, approximately a 8% to 43% change in width reduction percentage, approximately a 2% to 15% change in wall thickness reduction percentage, and approximately a 4% to 75% change in anisotropy. 805-812. (canceled)
 813. An expandable tubular member comprising: a tensile strength of approximately 68 to 115 ksi before radial expansion; a tensile strength of approximately 80 to 120 ksi after 15.2 to 16% radial expansion; and a tensile strength of approximately 82 to 121 ksi after 24 to 25.2% radial expansion. 814-816. (canceled)
 817. An expandable tubular member comprising: a tensile strength of approximately 100 to 114 ksi before radial expansion; and a tensile strength of approximately 126 to 140 ksi after 15.6 to 31.3% radial expansion.
 818. (canceled)
 819. An expandable tubular member comprising: upon quenching in water at approximately 735 to 775° C., a tensile strength of 94 ksi and a yield strength of 56 to 59 ksi. 820-821. (canceled)
 822. An expandable tubular member comprising: upon quenching in oil at approximately 750 to 820° C., a tensile strength of 84 to 109 ksi and a yield strength of 49 to 61 ksi. 823-824. (canceled)
 825. An expandable tubular member comprising: by weight percentage, 0.1% C, 1.5% Mn, and 0.3% Si.
 826. (canceled)
 827. An expandable tubular member comprising: a yield strength of approximately 46 to 90 ksi; a yield strength to tensile strength ratio of approximately 0.69 to 0.88; a longitudinal elongation change due to radial expansion of approximately 14.8 to 49.0%; a width reduction due to radial expansion of approximately 22 to 50%; a wall thickness reduction due to radial expansion of approximately 20 to 53%; and an anisotropy of approximately 0.63 to 1.1. 828-830. (canceled)
 831. An expandable tubular member comprising: an elongation change due to radial expansion of approximately 21%; a width reduction due to radial expansion of approximately 35%; a wall thickness reduction due to radial expansion of approximately 38%; and an anisotropy of approximately 0.89.
 832. An expandable tubular member, upon quenching and tempering, comprising: after a flare expansion of 42% to 52%; an absorbed energy in the longitudinal direction of 85 to 145 ft-lbs; an absorbed energy in the transverse direction of 59 ft-lbs; and an absorbed energy in the weld of 174 to 176 ft-lbs. 833-848. (canceled) 